Upper for an article of footwear

ABSTRACT

An upper for an article of footwear includes a spray formed first layer including a first material, and a second layer including a second material, the second layer being adhered to the first layer. A transition zone is defined at a transition between the first layer and the second layer, and the transition zone includes a mixture of the first and second materials.

FIELD OF THE INVENTION

The present invention relates to forming an article of footwear and, inparticular, to forming an upper via a deposition process and theresulting article.

BACKGROUND

Articles of footwear typically include an upper and a sole structureattached in some manner to the upper. For example, an article offootwear or shoe typically includes an upper secured (e.g., via adhesiveand/or stitching) to a sole structure that can include a midsole (toprovide a level of cushioning to a user depending upon a particular use)and an outsole to provide a certain level of traction and/or wearresistance to the bottom of the shoe.

The upper can be formed from a number of different types of materialsdepending upon the desired features of the upper. For example, the uppercan be formed of natural or synthetic polymer materials that are eithermolded to form the upper or formed from filaments or fibers (e.g., usinga knitting or weaving process). Further, uppers can be formed withlayers of materials, such as materials that include fabric layers withfoam and/or other types of cushioning materials provided between thefabric layers. Further still, the outer surface of an upper can becontoured with different patterns or designs, sometimes very intricatedesign patterns that increase the complexity of the manufacturingprocess used to form the upper.

Manufacturing uppers having different features, made of differentmaterials and/or having different layers for particular end uses can bea difficult and time consuming process which can also include humaninteractions at a number of stages during the manufacture process. Thiscan in turn make it difficult to mass produce certain types of shoes.

SUMMARY OF THE INVENTION

In example embodiments, an upper for an article of footwear comprises aspray formed first layer comprising a first material, and a second layercomprising a second material, the second layer being adhered to thefirst layer. A transition zone is defined at a transition between thefirst layer and the second layer, and the transition zone comprises amixture of the first and second materials.

In some example embodiments, the first layer includes an exposed surfacethat defines an exterior of the upper, and the exposed surface includesthree dimensional structural surface components disposed at portions ofthe exposed surface.

The present invention facilitates a number of advantages in forming anupper and/or combined upper and sole structure for a shoe. For example,detailed and intricate structural features can be easily formed on anexterior surface of the upper based upon corresponding (but reversed orinverted) structural features provided on the last used to spray formthe upper. Internal structural features (i.e., structural featuresprovided between inner and outer layers of the upper) can also be easilyintegrated within the upper in accordance with techniques describedherein.

The above and still further features and advantages of the presentinvention will become apparent upon consideration of the followingdetailed description of specific embodiments thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are side views of an upper for a shoe formed with thespray deposition process in accordance with an embodiment of theinvention as described herein.

FIG. 1C is an enlarged view of a side portion of the upper of FIG. 1Ashowing structural features formed on the exterior surface of the upper.

FIGS. 2A and 2B are views of opposite sides of a shoe last used to formthe upper of FIG. 1A.

FIG. 2C is an enlarged view of a side portion of the shoe last of FIGS.2A-2B showing structural features disposed on the exterior surface ofthe shoe last that define an inverted contour or “negative image”pattern that forms structural features for exterior surface portions ofthe shoe last as shown in FIG. 1C.

FIGS. 3A and 3B are side views of another embodiment of an upper for ashoe formed with the spray deposition process in accordance with theinvention as described herein.

FIG. 3C is an enlarged view of a portion of the upper of FIGS. 3A-3Bshowing structural surface features formed on the exterior surface ofthe upper.

FIGS. 4A and 4B are side views in perspective of a shoe last used toform the upper of FIGS. 3A and 3B.

FIG. 4C is an enlarged view of an exterior side surface portion of theshoe last of FIGS. 4A-4B showing structural features for the shoe lastthat form the respective structural feature patterns on the exteriorsurface of the upper as depicted in FIG. 3C.

FIGS. 5A and 5B are side views of a further embodiment of an upper for ashoe formed with the spray deposition process in accordance with theinvention as described herein.

FIG. 5C is an enlarged view of a portion of the upper of FIGS. 5A and 5Bthat is located along an exterior side surface (e.g., along views asdepicted in FIGS. 5A and 5B) showing structural surface features formedon the exterior surface of the upper.

FIG. 5D is an enlarged view of a portion of the upper of FIGS. 5A and 5Bthat is located along an exterior surface of a toe portion (e.g., alongthe view depicted in FIG. 5B) showing structural surface features formedon the exterior surface of the upper.

FIG. 5E is an enlarged view of a portion of the upper of FIGS. 5A and 5Bthat is located along an exterior surface of a heel portion (e.g., alongthe view depicted in 5B) showing structural surface features formed onthe exterior surface of the upper.

FIG. 5F is a side view in perspective of the upper of FIGS. 5A and 5Band further showing a transition of an exterior surface pattern for thepatterns depicted in FIGS. 5C-5E at different zones of the upper.

FIGS. 6A-6D are different views of a shoe last used to form the upper ofFIGS. 5A-5D.

FIG. 6E is an enlarged view of an exterior side surface portion of theshoe last of FIGS. 6A-6D showing structural features for the shoe lastthat form the respective structural feature patterns on exterior surfaceportions of the upper as depicted in FIG. 5C.

FIG. 6F is an enlarged view of an exterior side surface portion of theshoe last of FIGS. 6A-6D showing structural features for the shoe lastthat form the respective structural feature patterns on exterior surfaceportions of the upper as depicted in FIG. 5D.

FIG. 6G is an enlarged view of an exterior side surface portion of theshoe last of FIGS. 6A-6D showing structural features for the shoe lastthat form the respective structural feature patterns on exterior surfaceportions of the upper as depicted in FIG. 5E.

FIG. 7 is an example embodiment showing a cross-sectional view of aportion of an upper showing various layers that form the upper.

FIG. 8 is a flowchart that sets forth method steps for spray coatforming of an upper in accordance with an embodiment of the invention asdescribed herein.

FIG. 9 is a flowchart setting forth an example embodiment ofpre-treatment steps for treating the last prior to spray forming ofstructural layers of the upper on the last.

FIGS. 10A-10D depict automated processing steps for forming an upper inaccordance with an embodiment of the invention as described herein, inwhich a robotic arm spray application is used to spray form layers on alast to form the upper.

FIGS. 11A-11C depict a series of steps in a manufacturing process of aspray formed upper in which structural components (eyelet reinforcingmembers) are embedded between spray formed layers of an upper inaccordance with an embodiment of the invention.

FIGS. 12A-12C depict a series of steps in a manufacturing process of aspray formed upper in which structural components (e.g., a heel counter,lateral and/or medial side structural support elements, and a toe cagereinforcing protection element) are embedded between spray formed layersof an upper in accordance with another embodiment of the invention.

FIGS. 13A-13D depict a series of steps in a manufacturing process of aspray formed upper in which openings or windows can be formed within aspray formed layer (e.g., an exterior layer) of the upper to expose anunderlying layer (e.g., a nonwoven or other fibrous fabric materiallayer) of the upper in accordance with an embodiment of the invention.

FIGS. 14A-14E depict a series of steps in a manufacturing process of aspray formed upper in which openings or windows can be formed within aspray formed layer (e.g., an exterior layer) of the upper to exposeunderlying and structural elements (e.g., pieces of nonwoven or otherfibrous fabric materials) partially embedded within the upper inaccordance with an embodiment of the invention.

FIG. 15 depicts a flowchart that sets forth method steps for forming ashoe including a spray formed upper and a sole structure spray formed onor injection molded to the upper in accordance with embodiments of theinvention.

FIGS. 16A-16C depict a series of process steps for forming a shoeutilizing the process depicted in the flowchart of FIG. 15.

In the following detailed description, reference is made to theaccompanying figures which form a part hereof wherein like numeralsdesignate like parts throughout, and in which is shown, by way ofillustration, embodiments that may be practiced. It is to be understoodthat other embodiments may be utilized, and structural or logicalchanges may be made without departing from the scope of the presentdisclosure. Therefore, the following detailed description is not to betaken in a limiting sense, and the scope of embodiments is defined bythe appended claims and their equivalents.

DETAILED DESCRIPTION

Aspects of the disclosure are disclosed herein. Alternate embodiments ofthe present disclosure and their equivalents may be devised withoutparting from the spirit or scope of the present disclosure. It should benoted that any discussion herein regarding “one embodiment”, “anembodiment”, “an exemplary embodiment”, and the like indicate that theembodiment described may include a particular feature, structure, orcharacteristic, and that such particular feature, structure, orcharacteristic may not necessarily be included in every embodiment. Inaddition, references to the foregoing do not necessarily comprise areference to the same embodiment. Finally, irrespective of whether it isexplicitly described, one of ordinary skill in the art would readilyappreciate that each of the particular features, structures, orcharacteristics of the given embodiments may be utilized in connectionor combination with those of any other embodiment discussed herein.

For the purposes of the present disclosure, the phrase “A and/or B”means (A), (B), or (A and B). For the purposes of the presentdisclosure, the phrase “A, B, and/or C” means (A), (B), (C), (A and B),(A and C), (B and C), or (A, B and C).

Further, the terms “comprising,” “including,” “having,” and the like, asused with respect to embodiments of the present disclosure, aresynonymous.

Initially, it is noted that the figures depict embodiments of an upperor an article of footwear including an upper and sole structure andfurther embodiments of a last for three dimensionally spray forming anupper and/or upper with sole structure for a single foot (e.g., anupper, an upper with sole structure, or a last for a left foot or,alternatively, for a right foot of a user). However, it is noted thatthe same or similar features can also be provided for a last or an upperor upper with sole structure that forms an article of footwear (shoe)configured for the opposing foot (e.g., for the opposing right or leftfoot of a user), where such features of the upper, upper with solestructure and last forming the upper and/or sole structure for the otherfoot can be a reflection or can be “mirror image” symmetrical inrelation to the last, upper and/or sole structure depicted in thefigures.

As described herein with reference to the example embodiments of thefigures, an article of footwear or shoe is formed with an upper that isformed via a liquid particle deposition or spray forming process. Inparticular, one or more layers are sprayed or spray deposited onto afootwear or shoe mold, also referred to herein as a “shoe last” or a“last”, to form the upper. The spray forming process can comprisespraying/depositing droplets of polymer material onto the last to buildup/form a layer of a desired thickness. Further layers can be sprayformed or applied in any other suitable manner over a spray formed layerso as to form a multi-layered upper structure on the last. The sprayformed upper can be combined in any conventional or other suitablemanner with a sole structure (e.g., a sole structure including a midsoleand/or an outsole) to form the shoe. In other embodiments, an entireshoe, including upper and sole structure (i.e., midsole and/or outsole),can be formed by a spray forming process as described herein.

As described herein, the spray coating or spray deposition process, alsoreferred to herein as spray forming, of the present invention is used toform one or more layers over a shoe last by depositing polymer material(e.g., deposited from a spray nozzle) onto the last. The polymermaterial can be deposited in solid (e.g., solid fibers or filaments),semi-solid (e.g., partially solid polymer material) and/or liquid statein the spray deposition process. After the polymer material is depositedas one or more layers over selected portions of the shoe last, thepolymer material is sufficiently set, solidified or cured/hardened toform at least a portion of an upper. The upper is removed from the lastand further processed as necessary for a particular embodiment to formthe shoe. The spray forming process to form a layer over the lastcomprises building up the layer (i.e., increasing a thickness of thelayer) by depositing material that forms the layer onto or over the lastuntil a layer of sufficient or desired thickness is achieved.

As discussed in greater detail, below, a composite article of footwearor a component thereof (e.g., an upper) is created utilizing a sprayprocess in which a polymer is atomized to produce a jet of fineparticles (e.g., liquid droplets optionally with solid filaments orfibers suspended therein). The atomized polymer is applied to a surface(e.g., a mechanical form or mold configured in the shape of a human footto define a shoe last). The polymer is applied via one or more passes toform a coating having a predetermined thickness. In particular, multiplecoatings may be applied utilizing different polymer compositions to formadditional build layers. The texture on the last may include both amacrostructure (large scale protrusions defining valleys and hillscapable of preventing tears along the composite), as well asmicrostructure (surface texture providing tactile sensation orincreasing the surface roughness on the macrostructure).

EXAMPLE EMBODIMENTS OF SPRAY FORMED SHOE UPPERS

Some examples of uppers formed using a spray deposition processaccording to the invention and having intricate exterior surfacestructural features are described with reference to FIGS. 1A-1C, 3A-3Cand 5A-5E. As described herein, the upper of FIGS. 1A-1C is formed witha last as depicted in FIGS. 2A-2C, while the upper of FIGS. 3A-3C isformed with a last as depicted in FIGS. 4A-4C and the upper of FIGS.5A-5E is formed with a last as depicted in FIGS. 6A-6G. The uppers areformed using a spray deposition process as described herein, whereexterior surface portions of each upper can include elaborate andintricate three dimensional structural features (e.g. structuralfeatures as depicted by the exterior upper surface patterns as depictedin the enlarged views of FIGS. 1C, 3C, and 5C-5E). While the uppersdepicted in FIGS. 1, 3 and 5 (with the exception of FIG. 5E) show onlysmall portions of the exterior surfaces of the uppers having threedimensional exterior structural surface features, such features can bedisposed about any selected portions (e.g., some or all) of the exteriorsurface for each of the uppers. This is further indicated in the lastsdepicted in FIGS. 2, 4 and 6 (which show exterior structural surfacefeatures over the surfaces of the lasts).

Referring to FIGS. 1A and 1B, an upper 100 is formed utilizing a sprayforming or spray deposition process as described herein and includesexterior surface structural features comprising a repeating pattern ofrib-like structures and channels or indentations along the exteriorsurface of the upper. The upper 100 includes a front or forefoot region112 that generally aligns with the ball and toes of a user's foot (i.e.,when a user is wearing the upper), a midfoot region 114 that generallyaligns with the arch and instep areas of the user's foot, and a hindfoot region 116 that generally aligns with the heel and ankle areas ofthe user's foot. The upper 100 further includes a medial side 120 thatis oriented along the medial or big toe side of the user's foot, alateral side 130 that is oriented along the lateral or little toe sideof the user's foot, a toe (i.e., front) end 140 or toe cage thatcorresponds with the toe end of the user's foot and a heel (i.e., rear)end 150 that corresponds with the heel of the user's foot. The heel end150 has a curved shape defining a heel cup that generally conforms tothe user's heel and extends between the medial and lateral sides 120,130 of the upper 100. A main opening at a top or neck portion of theupper 100, which is defined between the toe end 140, heel end 150,medial and lateral sides 120, 130 provides access to a cavity of theupper that is configured to receive the user's foot. The midfoot region114 further includes a vamp section extending from the toe cage towardthe neck portion of the upper, where the vamp section of the upper 100includes an open section defined between the upper edges of the medialand lateral sides 120, 130 and that extends to the main opening of theupper. The medial/lateral side upper edges can include cut-out holes oreyelets 155 that are suitably aligned and dimensioned to receive a shoelace or other fastener that firmly secures the user's foot within theupper (i.e., by pulling or cinching the lateral and medial sides towardeach other using the shoe lace or other fastener). In certainembodiments, a tongue member that is not formed contiguously or integralduring the spray forming process with the other portions of the uppercan nevertheless be secured at the open vamp section of the upper 100.In other embodiments (e.g., refer to the upper of FIGS. 3A-3C and FIGS.5A-5G as described herein), a tongue portion can be integrally formedwith other portions of the upper using the spray forming process asdescribed herein.

Some or all of the exterior surface portions of the upper 100 of FIGS.1A and 1B include a number of exterior surface features that are formedon the upper utilizing the spray forming process as described herein. Apartial enlarged view of a portion (indicated as portion 102 on sides ofthe upper 10) of the exterior surface of the upper 100 is depicted inFIG. 1C, in which a repeating unit of the structural features is shown.The enlarged portion 102 includes a repeating pattern unit that isrepeated over some or all of the exterior surface of the upper 100(e.g., over the lateral and medial sides, over the toe cage and vampsections, and around the heel end of the upper). Alternatively, therepeating pattern unit depicted in portion 102 can repeat along certainexterior surface area portions of the upper while other exterior surfacearea portions can include other exterior surface structural features(e.g., other repeating exterior surface patterns) or can remainrelatively smooth (i.e., not structural surface features at suchexterior surface portions).

As depicted in FIG. 1C, the repeating pattern unit shown in enlargedportion 102 includes a series of elongated, raised rib-like structures160 (also referred to herein as ribs) and a series of grooves orchannels 170 defined between the ribs 160, where the ribs 160 andchannels 170 are formed along some or all portions of the exteriorsurface of the upper (e.g., along the medial side 120, lateral side 130,toe end 140 and heel end 150). The pattern unit 102 including ribs 160and channels 170 can be formed in an array or repeating pattern alongthe upper exterior surface (e.g., with some ribs connecting with eachother to form series of interconnected rectangular or square structuresand corresponding channels arranged in similar patterns between theribs). However, any suitable arrangement of structures can be formed onany one or more exterior surface portions of the upper, where thearrangement of structures can change in configuration (e.g., change inpatterns, shapes of ribs and/or channels, etc.) at different locationsof the upper. Ribs and/or other structural features provided on theexterior surface of the upper provide certain functional features forthe upper as described in further detail herein.

Referring to FIGS. 3A-3C, another embodiment is depicted of an upper 300formed utilizing a spray forming/spray deposition process as describedherein. The upper 300 includes the same or similar regions as describedfor the upper 100 of FIGS. 1A and 1B, namely, a forefoot region 312, amidfoot region 314 and a hind foot region 316, as well as a medial side320, a lateral side 330, a toe cage or toe end 340 and a rear or heelend 350. The upper 300 further includes a tongue member 345 that isformed integrally and contiguously during the spray forming process withthe other portions of the upper 300, where the tongue member 345 extendsin the vamp section of the upper between the upper edges of the medialand lateral sides 320, 330 and from a region of the toe end 340 to anopening at a neck portion of the upper that receives a wearer's foot.The upper 300 further includes openings at the upper edges of the medialand lateral sides that define eyelets 355, where the eyelets 355 aresuitably aligned and dimensioned to receive a shoe lace or otherfastener.

The upper 300 also includes exterior surface features that form apattern along portions of the upper. A repeating unit of the exteriorsurface patterns is depicted in the enlarged view of FIG. 3C (whichshows an exterior surface portion 302 of the upper 300). Similar toupper 100, the repeating pattern unit included in the enlarged exteriorsurface portion 302 of the upper 300 can continuously repeat along someor all of the exterior surface of the upper 300 (e.g., along the lateraland medial sides, along the toe cage, the vamp section and/or along theheel end of the upper 300).

The repeating pattern unit included in enlarged portion 302 depicted inFIG. 3C comprises a series of polygonal (e.g., hexagonally) shapedstructures 310 of different sizes that are nested within each other andform raised or stepped portions and depressions along exterior surfaceportions of the upper. Like the exterior structural features describedherein and depicted in the repeating pattern unit of FIG. 1C, theexterior surface structural features depicted in the repeating patternsof FIGS. 3C and 3D can also provide certain functional features of theupper as described herein.

A still further embodiment is depicted in FIGS. 5A-5F of an upper 500that is formed utilizing a spray forming/spray deposition process asdescribed herein. The upper 500 also includes the same or similarregions as described for the other two uppers of FIGS. 1 and 3, namely,a forefoot region 512, a midfoot region 514 and a hind foot region 516,as well as a medial side 520, a lateral side 530, a toe cage or toe end540 and a rear or heel end 550. The upper 500 further includes a tonguemember 545 that is formed integrally and contiguously during the sprayforming process with the other portions of the upper 500, where thetongue member 545 extends in the vamp section of the upper between theupper edges of the medial and lateral sides 520, 530 and from a regionof the toe end 540 to an opening at a neck portion of the upper thatreceives a wearer's foot. The upper 500 further includes openings at theupper edges of the medial and lateral sides that define eyelets 555,where the eyelets 555 are suitably aligned and dimensioned to receive ashoe lace or other fastener.

The upper 500 includes a plurality of different pattern units (somerepeating pattern units) disposed along different exterior surfaceportions of the upper. The different surface portions of the upperincluding different exterior surface patterns comprise different zonesor different zonal areas of the upper, where the different zones canprovide different functional features for the upper. The views of FIGS.5C, 5D and 5E depict examples of exterior surface portions or zones ofthe upper 500 that include different repeating patterns that providedifferent functional features for the upper.

Referring to FIG. 5C, an upper exterior surface portion 502 includes arepeating pattern unit that comprises a series of triangular shaped orwavy ridges 503 that extend three dimensionally outward from other,relatively flat or smooth exterior surface portions of the upper 300 soas to define an uneven contour along exterior surface portions of theupper. This repeating pattern unit of portion 502 extends along exteriorsurface portions of the medial side 520 and lateral side 530 of theupper 500. The three dimensional surface pattern of this repeatingpattern unit can enhance the features of the upper when provided alongthe medial and lateral sides of the upper. In particular, the threedimensional surface pattern (the triangular shaped or wavy ridges 503)can comprise a three dimensional auxetic pattern (i.e., the patternincludes three dimensional auxetic structures). Generally, auxetics arestructures or materials that have a negative Poisson's ratio such that,when stretched, they become thicker perpendicular to the applied force.The auxetic patterning of the exterior surface structural featuresdepicted in surface portion 502 can be applied, e.g., along both thelateral and medial sides of the upper 500 so as to increase or enhancethe support and fit of the upper against the wearer's foot during use.

Referring to FIG. 5E, an upper exterior surface portion 506 includes aplurality of raised structures having a pattern of intersecting rib-likestructures that define diamond shaped depressions between the rib-likestructures, where the pattern extends along both lateral and medialsides 520, 530 at the end heel 550 of the upper 500. The exteriorsurface pattern can be configured to enhance the strength and support atthe heel end 550 of the upper 500 (e.g., providing the functionalfeatures of a heel counter for the upper).

Referring to FIG. 5D, disposed along one or both of the medial side 520and lateral side 530 at the front or toe end 540 of the upper 500 is apattern unit that comprises a series of semicircular or arc shaped ribswith corresponding arc shaped grooves defined between neighboring oradjacent ribs, where the ribs and grooves are concentrically alignedwith each other (e.g., a truncated or halved spiral pattern, or a radialpattern of ribs and corresponding grooves). This radial pattern of ribsand grooves provides an enhanced gripping surface (enhanced traction atsuch surface) for contact with objects such as balls (e.g., a soccerball) when the upper is implemented in a shoe for use in certain sportsor other athletic activities.

The transition between different pattern units, such as those depictedin FIGS. 5C-5E, can be achieved in any desired manner. Referring to FIG.5F, an example embodiment is depicted showing the transition of patternunits/repeating patterns between different zones or zonal areas of theupper 500. For example, the pattern unit 504 at the toe end changes torepeating pattern unit 502 along the side of the upper 500 and then torepeating pattern unit 506 at the heel end of the upper 500.

The embodiments of a shoe upper depicted in FIGS. 1, 3 and 5 are formedsuch that substantially the entire upper is formed as a single,continuous or unitary three dimensional member with the exception that abottom portion of the upper is unformed/open. In such embodiments, theupper can be secured to a strobel or other suitable bottom surfacemember for attaching the upper to a sole structure. However, the sprayforming process as described herein can also facilitate the formation ofa bottom surface for the upper such that the entire upper is formed as asingle, continuous or unitary member (including bottom surface, i.e.,forming an enclosed sock-like structure as the spray formed upper).Further, the three dimensional exterior surface structural features orcomponents defined on the uppers can be disposed along a majority (e.g.,at least 50%) of the surface area of the upper.

EXAMPLE EMBODIMENTS OF SHOE LASTS USED TO SPRAY FORM UPPERS

As previously noted and as further described herein, the uppers of FIGS.1, 3 and 5 can be formed utilizing a spray forming process by spraycoating/depositing one or more suitable materials on a mold or shoelast, such as the shoe lasts depicted in FIGS. 2A-2C, FIGS. 4A-4C andFIGS. 6A-6G.

A shoe last (also referred to as a last) refers to a mold that can besolid or hollow and has a three dimensional shape that facilitatesspraying of one or more layers of materials onto exterior surfaceportions of the last that, when set or solidified, can be removed fromthe last so as to define the upper. In particular, the shoe last has athree dimensional shape that generally conforms to the three dimensionalshape of the upper to be formed. Further, the last can comprise asingle, unitary mold structure or, alternatively two or more separatemold structures depending upon the types of structural features and/orlayers of material that are desired for the upper to be spray formed.For example, in embodiments in which the shoe last comprises two or moremold structures, the mold structures can be combined with each other inany suitable manner, such as in a clam shell configuration (e.g., aninternal mold nested within and spaced from an external mold, where theupper is formed by spray depositing one or more layers of materialswithin the spacing between the two molds). In the embodiments depictedin the figures, the shoe last comprises a single unitary structure thatfacilitates spray forming of the upper onto the last followed by removalof the upper such that the upper is seamless.

Referring to FIGS. 2A-2C, an example embodiment is depicted of a last200 used to form the upper 100 of FIGS. 1A-1C. The last 200 has a threedimensional configuration generally corresponding with the shape of theupper 100 and thus includes the same or similar sections that correspondwith the same sections of the upper. In particular, the last 200includes a medial forming side 220 that corresponds in shape with themedial side 120 of the upper 100, a lateral forming side 230 thatcorresponds in shape with the lateral side 130 of the upper 100, a toeend 240 that corresponds in shape and location with the toe end 140 ofthe upper 100, and a heel end 250 that corresponds in shape and locationwith the heel end 150 of the upper 100. The last 200 further includes abottom side (not shown).

The last 200 further includes structural features on portions of itsexterior surface that correspond with the pattern 102 of ribs 160 andchannels 170 of the upper 100. In example embodiments, the repeatingpattern of three dimensional structural features and/or other threedimensional structural features can be provided on at least about 10% ofan exterior surface area of the last, such as at least about 25% of theexterior surface area of the last, at least about 50% of the exteriorsurface area of the last, or at least about 75% of the exterior surfacearea of the last that does not include the bottom side of the last.

A comparison of the surface patterns depicted in FIG. 1C for the upper100 and FIG. 2C for the last 200 indicates that the exterior surfacestructural features of the last 200 are inverted/reversed in contour inrelation to corresponding exterior structural surface features of theupper 100. This is due to the manner in which the upper is formed asdescribed in further detail herein, where one or more layers ofmaterials are spray formed onto exterior surface portions of the last200 to form the upper and the resultant spray formed upper structure isremoved from the last and turned inside out to define the upper (e.g.,the surface of a first or initial layer formed by spray deposition anddirectly contacting the last 200 becomes the outer or exterior layer ofthe upper 100 after the upper is removed from the last 200 and is turnedinside out). The upper that is formed is therefore the inverted form ofthe last used to form the upper. In other words, a right footed shapedlast forms a left footed upper (and, similarly, a left footed shapedlast forms a right footed upper) using the process described herein inwhich the upper is turned inside out after being removed from the last.

Referring to FIGS. 2A and 2B, the medial and lateral forming sides 220,230 of the last 200 correspond with the medial and lateral sides 120,130 of the formed upper 100. Further, the structural features of thelast 200, namely rib-like structures or ribs 270 and channels 260 asshown in FIG. 2C, are inverted or reversed in surface contour inrelation to the ribs 160 and channels 170 of the upper 100. In otherwords, the channels 260 on the last 200 define the ribs 160 on the upper100, while the ribs 270 on the last 200 define the channels 170 on theupper 100. Such inversion or reversal of surface contour for theexterior surface structural features for one of the last and the upperis also referred to herein as being a reverse image or a “negativeimage” of the corresponding exterior surface structural features for theother of the last and the upper.

In example embodiments, the structural features for the last 200 (e.g.,ribs 270 and channels 260) can extend along each of the medial formingside 220, lateral forming side 230, toe end 240 and heel end 250 of thelast 200. The bottom side of the last 200 can relatively smooth (i.e.,no structural features provided on the last bottom side). In alternativeembodiments, the bottom side of the last can also be presented withexterior surface structural features (e.g., structural features that maybe imparted to the bottom surface of a spray formed upper that enhancesecuring of the upper to a sole structure). In addition, located alongthe upper portions of each of the lateral and medial forming sides ofthe last 200 are a series of generally elongated (e.g., cylindrical)protrusions 255. As described herein, when an upper (e.g., upper 100) isspray formed on the last 200, openings or eyelets are defined along theupper (e.g., eyelets 155 of upper 100) at locations corresponding withthe protrusions 255 of the last 200.

The last 400 depicted in FIGS. 4A-4B is used to form the upper 300 ofFIGS. 3A-3B. Like the last 200 of FIGS. 2A-2B, last 400 also has a threedimensional configuration that, while inverted in contour (since theupper 300 is turned inside out when it is removed from the last afterbeing formed), generally corresponds with the shape of the upper 300 andthus includes the same or similar sections that correspond with the samesections of the upper (i.e., including a medial forming side 420, alateral forming side 430, a toe end 440 and a heel end 450 all of whichcorrespond in shape with the complimentary sides of the upper 300). Thelast 400 further includes a bottom side (not shown). The last 400 alsoincludes generally cylindrical protrusions 455 located at upper sideportions of the lateral and medial forming sides, where the protrusions455 facilitate formation of the eyelets 355 for the upper 300.

The last 400 also includes a tongue forming portion 445 that extendsupward and outward in a wing-like manner from a upper shaped main bodyportion of the last 400 at a location between the lateral and medialforming sides 420, 430 and at a vamp section between the toe end 440 andheel end 450 of the last. The shape of an upper/outwardly facing surface446 of the tongue forming portion 445 has a shape that conforms to (andthus facilitates formation of) the tongue portion 345 of the last 300.The edges of the outwardly facing surface 446 of the tongue formingportion 445 can also be slightly raised to define a sharply angledtransition to other surface portions of the tongue forming portion thatextend from the surface 446 back toward the main body of the last 400.As described herein, this angled transition provides cut-in lines forthe spray formed tongue of the upper that enhances separation betweenthe tongue portion 345 and outwardly facing surface 446 of the tongueforming portion 445 during removal of the spray formed upper from thelast.

Also similar to the last 200, last 400 includes a surface contour withexterior surface structural features that are inverted in contour inrelation to (i.e., are a reverse image or a “negative image” of) thecorresponding exterior surface structural features for the upper 300that is formed using the last 400 with a spray forming process asdescribed herein. Referring to FIG. 4C, an enlarged view of an exteriorsurface portion 402 of the last 400 shows a repeating pattern for thelast. The exterior surface portion 402 includes stepped hexagonalstructures 410 that are inverted/opposite in three dimensional contourin relation to corresponding hexagonal structures 310 at thecorresponding exterior surface portions 302 of the upper 300. Inparticular, the pattern of exterior surface structural features of FIG.4C is the negative image (i.e., facilitates formation) of the pattern ofexterior surface structural features depicted in FIG. 3C for the upper300. Like the last 200, the repeating pattern of three dimensionalstructural features and/or other three dimensional structural featuresfor the last 400 can be provided on at least about 10% of the exteriorsurface of the last, such as at least about 25% of the exterior surfaceof the last, at least about 50% of the exterior surface of the last, orat least about 75% of the exterior surface of the last that does notinclude a bottom side of the last.

The last 600 depicted in FIGS. 6A-6G is used to form the upper 500 ofFIGS. 5A-5E. As with the other lasts described herein, last 600 also hasa three dimensional configuration that, while inverted in contour (sincethe upper 500 is turned inside out when it is removed from the lastafter being formed), generally corresponds with the shape of the upper500 and thus includes the same or similar sections that correspond withthe same sections of the upper (i.e., including a medial forming side620, a lateral forming side 630, a toe end 640 and a heel end 650 all ofwhich correspond in shape with the complimentary sides of the upper500). The last 600 further includes a bottom side (not shown). Like theother lasts, last 600 also includes generally cylindrical protrusions655 located at upper side portions of the lateral and medial formingsides, where the protrusions 655 facilitate formation of the eyelets 555for the upper 500.

The last 600 also includes a tongue forming portion 645 that is locatedbetween the lateral and medial forming sides 620, 630 and at a vampsection between the toe end 640 and heel end 650 of the last. However,unlike last 400, the tongue forming portion 645 of last 600 follows thegeneral contour of the vamp section of the last (i.e., portion 645 doesnot extend outward in a wing-like manner as portion 445 does for last400). This portion 645 facilitates formation of the tongue 545 of theupper 500.

Last 600 also includes a surface contour with exterior surfacestructural features that are inverted in contour in relation to (i.e.,are a “negative image” of) the corresponding exterior surface structuralfeatures for the upper 500 that is formed using the last 600 with aspray forming process as described herein. Referring to FIGS. 6E, 6F and6G, enlarged views of exterior surface portions 602, 604 and 606 of thelast 600 are depicted which are inverted in contour in relation to(i.e., negative images of) the corresponding patterns depicted in theexterior surface portions 502, 504 and 506 of the upper 500 as depictedin FIGS. 5C, 5D and 5E.

Similar to the other lasts, the repeating pattern of three dimensionalstructural features and/or other three dimensional structural featuresfor the last 600 can be provided on at least about 10% of the exteriorsurface of the last, such as at least about 25% of the exterior surfaceof the last, at least about 50% of the exterior surface of the last, orat least about 75% of the exterior surface of the last that does notinclude a bottom side of the last. As noted for the upper 500, some ofthe patterns (e.g., the pattern unit of surface portion 602 depicted inFIG. 6E) are repeating pattern units over exterior surface portions ofthe last (e.g., over the lateral and medial side forming portions of thelast) while other pattern units (e.g., the pattern unit of exteriorsurface portion 604 of FIG. 6F) are only at one or more selectedlocations along the exterior surface of the last.

A shoe last can be formed in any suitable manner and utilizing anysuitable materials that ensure the integrity of the last during theformation of an upper on the last with a spray forming method asdescribed herein. Some non-limiting examples of providing a shoe lastinclude: providing a last formed of a suitable polymer material (e.g., apolyamide, such as nylon) or a silicon based material, providing a lastmade of wood, and providing a last having a stainless steel or othersuitable metal surface. As described herein, the last can be a solidstructure or, alternatively, a hollow structure (e.g., a hollowstructure including an interior cavity that facilitates filling of thelast with a heating and/or cooling fluid and/or draining of sprayedmaterial from drainage channels extending from an exterior surfaceportion to a hollow internal portion of the last). Further still, thelast can have a clam shell configuration to facilitate formation of anupper and/or shoe between two molds of the clam shell configuration(e.g., where a portion of the upper is formed via one or more sprayformed layers). In an example embodiment, a hollow last is filledentirely or partially with a thermal treatment fluid (e.g., water or anyother suitable fluid that provides a desired heat transfer between thefluid and the last material). Suitable structure (e.g., a thermal fluidrecirculation system including piping to direct fluid into and out ofthe last interior cavity) can be provided to facilitate flow of thermalfluid through the last interior cavity in order to enhance heat exchangebetween the fluid and the last.

A polymer or silicon based last can be formed, e.g., by any suitablemethod, such as a 3D printing process, forming the last within a mold,etc. For example, forming a last using 3D printing techniquesfacilitates the formation of very fine, intricate and elaborate threedimensional exterior surface features that are transferred (as a“negative image”) to a surface of the upper that is spray formed on thelast.

The exterior metal surface last can also be formed via any suitablemanner in which the entire last is made of the metal (e.g., by a castingor machining process) or only the exterior surface of the last is metal(e.g., by covering some or all of a wood or polymer last structure witha metal layer via any suitable plating or other metal depositionprocess). The exterior structural features provided on the metal lastcan be formed in any suitable manner (e.g., via laser etching,mechanical etching, acid and/or other chemical etching, etc.).

Depending upon a particular application, the last can also be formed asa solid or hollow material. For example, for certain applications, itmay be desirable to allow for drainage of excess polymer spray materialfrom the last, where drainage holes are provided in and extending to ahollow interior of the last (with further drainage structure coupledwith the last to capture such excess polymer spray material). Providinga hollow last also reduces weight and/or can reduce material costassociated with the last (particularly when forming a metal last).

A metal last (or last having an exterior metal surfaces) can also havecertain advantages in that it has a very smooth and relatively nonporoussurface that enhances formation of a layer to the surface. In addition,the metal last can be heated quickly to a desired temperature (dependingupon the thermal conductivity of the metal material). Further, a metallast can be made hollow while maintaining sufficient strength of theouter shell and exterior surface. A polymer or silicon formed last canalso provide advantages in that exterior surface features on the lastcan be elaborate and easily formed (e.g., via 3D printing, etching,etc.).

Spray Forming an Upper

Example embodiments of spray forming an upper are described primarilywith reference to the last embodiment of FIG. 2. However, it is notedthat the spray forming process is applicable for forming uppers with anylast, including the lasts of FIGS. 4 and 6.

An upper can be formed by spraying each side of the last 200, includingthe bottom side, such that the upper in essence forms a sock-likestructure. Alternatively, the upper can be formed by spraying onlyportions of the last 200, such as all sides of the last 200 except forits bottom side. In such embodiments, the upper comprises a unitarymember that is three dimensional in shape and that is substantially orentirely seamless (such as the upper 100 depicted in FIGS. 1A and 1B).In other embodiments, the last 200 can be sprayed to form one or morelayers in any other manner such that the upper structure formed on andremoved from the last 200 can be removed to form a two dimensional andincomplete upper structure that is then combined with other upperstructures to form the final, three dimensional upper member.

In example embodiments, the composite upper is formed as a plurality ofmaterial layers that are built upon each other by applying successivecoats of atomized polymer compositions onto the last, thereby forming aseries of layers, with adjacent layers overlapping each other. Anexample upper, such as upper 100, can be formed from a plurality ofmaterial layers spray coated onto the last 200 and built upconsecutively one layer upon the next. The materials forming the variouslayers can be any suitable materials capable of being spray formed tocoat the last and then dried or hardened to from a solidified structurallayer of the upper. Some non-limiting example polymer materials that maybe used to form a layer of the upper by a spray forming process includepolyurethanes, polyolefins (e.g., polyethylene), polyesters (e.g.,polyethylene terephthalate) and polyethers.

In an embodiment, a synthetic skin formed of a polyurethane elastomerbased on polyisocyanate polyaddition products is utilized. The polyolcomponent and the isocyanate component are mixed and the resultantreaction mixture is sprayed onto the last. The polyol component thenreacts with the isocyanate component to form polyurethane. Theisocyanate may be selected from the group of aromatic isocyanates,aliphatic isocyanates, and combinations thereof. Examples of isocyanatesdiphenylmethane diisocyanates (MDIs), polymeric diphenylmethanediisocyanates (pMDIs), toluene diisocyanates (TDIs), hexamethylenediisocyanates (HDIs), dicyclohexylmethane diisocyanates (HMDIs),isophorone diisocyanates (IPDIs), and combinations thereof. The polyolmay include an aromatic polyol, an aliphatic polyol, polyether polyol,or a polyester polyol. The polyurethane elastomer composition may alsoinclude one of more additives. Commercially available examples of asprayable urethane elastomer are ELASTOSKIN® and ELASTOLLAN®, bothavailable from BASF, Wyandotte, Mich.

In operation, and as explained in greater detail below, spraypolyurethane skin is a process of spraying a thin film of elastomericpolyurethane (PU) onto the last. When the PU cures, the film is peeledoff of the mold in a single sheet (skin) and finished with a variety ofpost mold processes. The PU may be applied directly to the last, or moldrelease agent (sacrificial or otherwise) is first applied to the last.In further embodiments, a paint layer is applied before application ofthe PU layer to provide color to the finished composite upper. Sprayskin processes are capable of producing thin parts utilizing mold havingfine cavities and details. Injection molding process, in contrast, doesnot consistently fill out a mold cavity and, in particular, a moldcavity including fine textures. The spray skin process, then, cantransfer extremely fine detail from the mold face such as texture orgrain detail, company logos, etc. In addition, the layers of a sprayform process become chemically bonded to each other, avoiding the needto utilize adhesive layers to secure adjacent layers together.

In further embodiments, a layer is formed of polymer foam compositionsuch as a polyurethane foam. The polyurethane foam may include theisocyanate and the polyol forming the polyurethane elastomer, along witha blowing agent. The blowing agent includes physical blowing agents,chemical blowing agents, and combinations thereof. A commerciallyavailable example of a sprayable urethane foam is ELASTOFLEX®, availablefrom BASF, Wyandotte, Mich.

The layers that are spray formed with a suitable polymer material canvary in density as well as other structural properties so as to impartcertain physical features in the upper at the layers including, withoutlimitation, breathability, stiffness or flexibility, stretchability,moisture wicking properties, antimicrobial properties, etc. The layerscan further be formed by spray deposition of a polymer material as spraydroplets in a molten (or semi-molten) or liquid (orsemi-liquid/semi-solid) state onto the last, where the polymer materialcan be sprayed (e.g., in a single pass or in multiple passes) onportions of the last to build up a polymer layer having any desiredthickness (e.g., uniform thickness or varying thickness) at differentlocations along the last. For example, a layer having a small thicknessmay only require a single pass over portions of the last (or a very fewnumber of passes) to build up the desired thickness, whereas a layerhaving a larger thickness may require multiple passes (e.g., 2, 3, 4passes or even more passes) over certain portions of the last in orderto build up the desired thickness of the layer. Thus, the thickness anddensity of the sprayed on/spray formed layer is controlled based uponthe amount of spray droplets of polymer material applied at differentareas along the last, where the layer is continuously increased inthickness and/or density based upon the building up or successiveapplication of spray of polymer material to such areas.

Another option for forming a layer of the upper is to spray formelongated fibers or filaments comprising one or more different polymermaterials onto the last thus forming a nonwoven or other fibrous (e.g.,textile or fabric) material layer for selected portions of the upper. Asdescribed in further detail herein, any suitable process for sprayforming polymer filaments or fibers to form a nonwoven or other fibrousmaterial layer on a surface can be used in the methods described hereinto obtain a textile material layer of the upper comprising filaments orfibers. For example, as described herein, a process of spray forming anonwoven material layer can be achieved by spraying polymer filaments orfibers in a binder material onto the last (or over a layer alreadyformed on the last).

As further described herein, portions of a nonwoven or other fibrousmaterial layer that are preformed (i.e., already formed as a fabric ortextile material) can be embedded within spray formed layers or,alternatively, provided as an interior or exterior layer of the upper. Anonwoven material is a fabric material made from synthetic fibers orfilaments (e.g., continuous and/or staple fibers or filaments) that arecombined and entangled to form an integral unit. Other types of fibrous(e.g., textile or fabric) materials that can be embedded between sprayformed layers (or provided as an interior or exterior layer) of an upperinclude knitted fabric materials, woven fabric materials, andembroidered fabric materials. Knitted, woven, nonwoven and embroideredfabric materials are well known in the textiles art.

The filaments or fibers forming the nonwoven or other fibrous materiallayer can be synthetic filaments or fibers formed from any suitable oneor more types of polymer materials typically utilized for formingnonwoven fibrous webs including, without limitation, polyolefins (e.g.,polyethylene, polypropylene, etc.), polyesters (e.g., polyethyleneterephthalate), and polyamides (e.g., nylon), including fibercombinations that provide a desired elasticity to the nonwoven web suchas elastane fibers (e.g., elastic PU, such as the types commerciallyavailable as Lycra or Spandex). Alternatively, the filament or fiberscan also be natural filaments or fibers (e.g., formed from cotton, silk,etc.). By varying amounts and types of polymer or other materials (aswell as filament cross-sections of such polymer materials) within thefibers/filaments used to form the nonwoven web fibrous layer, variousphysical characteristics of this layer can be controlled (e.g.,breathability or air/moisture permeability, elasticity, moistureabsorption, etc.). In example embodiments, a nonwoven fibrous layer willalso provide greater breathability (e.g., greater air and/or moisturepermeability) through this layer than other sprayed polymer layers.

The materials can be selected to have suitable physical and chemicalproperties such that, upon being sprayed onto the last (or onto a layeralready formed on the last), different materials located at theboundaries of adjacent layers suitably adhere to each other via chemicalbonding and/or any other suitable adhesion mechanism such that theformed upper including layers of different materials comprises a singleunitary structure. As described herein, one layer can be sprayed ontoanother layer on the last while that layer is partially but notcompletely solidified and/or cured (e.g., the already formed layer ispartially cured and somewhat tacky) so as to enhance the interaction andadhesion between the materials at the boundaries of adjacent layers. Asfurther described herein, in certain embodiments a density gradient canbe defined at a transition boundary between two adjacent layers (e.g.,between a second sprayed layer subsequently spray formed over a firstsprayed layer).

One example upper product that can be formed utilizing the spray formingmethods described herein is an upper that has a combination of threelayers as depicted in the cross-sectional view of a portion of an upperin FIG. 7. For example, the upper can be formed so as to have anexterior or outer polymer skin layer, a central or intermediate layer ofpadding (e.g., open cell foam material such as PU foam), and an interiorlayer forming a lining or interior skin layer facing the user's foot(e.g., another polymer skin layer, such as PU or polyester, or anonwoven layer forming the interior lining of the upper). The embodimentof FIG. 7 is a three layer upper structure, in which the outer layerforms an outer “skin” layer of the upper, the intermediate (embedded)layer forms a softer, foam layer and the interior layer serves as aninterior soft lining facing the wearer's foot. All three layers(exterior, intermediate and interior) can be spray formed.Alternatively, any combination of one or more layers can be spray formedwhile one or more other layers is provided in another manner (e.g.,preformed and applied to last).

In operation, the layers are applied to the last in the desired order,forming a layer thereon. Referring to FIG. 7, the first or exteriorlayer 710, which is the first coating or layer applied (sprayed) on thelast 200 and includes structures on its exposed surface (e.g., ribs 160and channels 170 as shown for the upper 100 of FIGS. 1A-1C), can beformed from a polyurethane (PU) skin material of low thickness (e.g.,the first layer possesses a thickness that is less than the thickness ofthe second layer) so as to function as the external “skin” layer of theupper 100. The second (intermediate) or central coating (layer) 720 isapplied (spray formed) over the first coating (layer) 710 may be formedof a polymer foam material, such as a PU foam (e.g., a PU materialhaving a density that is less than the density of external PU skin layer710). The third or inner layer 730 of the upper, applied (via spraying)to the second, foam layer 720, is formed of a composition suitable as alining material (e.g., PU, polyolefin or polyether) that forms theinterior surface portion of the upper 100. Inner layer 730 can be formedfrom the same or different type of material as the exterior layer 710.In certain embodiments, the inner layer 730 can be formed from adifferent type of polymer material than the exterior layer 710 (e.g., asprayed polyester layer or a sprayed polyether layer) and/or can beformed as a nonwoven fibrous layer so as to provide an interior linerfor the upper that has a softer texture, a more breathable and/ormoisture absorbent surface against the user's foot placed within theupper. The exterior or skin layer (e.g., layer 710) of the upper can beconfigured to provide some or a majority of the physical properties ofthe spray formed upper (e.g., strength, flexibility, etc.). The interiorlayer (e.g., layer 730) can be configured as a soft and comfort layerthat functions as an interior lining of the upper (i.e., the surface ofthe upper that faces and/or engages the foot of the wearer of theupper).

In another embodiment, an upper can be spray formed as a two layerstructure. An example of a two layer structure is similar to the threelayer structure depicted in FIG. 7 with the exception that theintermediate or central layer 720 is not formed as part of the upper. Inthis embodiment, the outer or exterior layer can further serve as a“skin” layer (e.g., formed of a suitable PU or other polymer materialthat forms an external skin of the upper), while the second layer cancomprise a spray formed fibrous material layer such as the typesdescribed herein (e.g., a spray formed nonwoven layer that comprisesstaple synthetic fibers mixed or combined with a binder material).Another example of a two layer upper is a knitted (or other type offormed fabric) upper, in which a preformed, knitted fabric material isplaced over the last to form a first layer, and a polymer material isthen spray formed over the knitted fabric material. When the upper isremoved from the last and turned inside out, the knitted fabric materiallayer forms the exterior surface of the upper while the polymer materiallayer forms the interior liner layer for the upper.

However, while example embodiments of a three layer upper and a twolayer upper have been described, it is noted that the invention is notlimited to such examples but instead can include spray formed upperswith any number of layers that are spray formed or applied in any othermanner and embedded between other spray formed layers of the upper.

As described in more detail herein, each successive layer is applied(e.g., spray formed) over another layer that is partially or fully cured(e.g., with a buildup of a layer over another layer being formed byspray droplets being continuously deposited onto the last); accordingly,no adhesive layer is needed to secure adjacent layers together. Instead,depending upon how hardened or solidified the existing layer is when thesuccessive layer is spray formed onto such existing layer, a portion ofthe sprayed material forming the successive layer can combine orotherwise chemically or mechanically bond with the exposed surface ofthe existing layer upon which the successive layer is spray formed. Thiscan result in a slight overlap or embedding between contacting layersthereby forming a transition zone being defined at the boundary betweenthe two adjoining layers (e.g., as shown in FIG. 7, a transition zone740 is located at the slight overlapping boundary between layer 720 andlayer 730, and a transition zone 735 is located at the slightoverlapping boundary between layer 720 and layer 710).

An example embodiment of a spray forming process utilizing a last (e.g.,last 200 as depicted in FIGS. 2A-2C, a last 400 as depicted in FIGS.4A-4C, or a last as depicted in FIGS. 6A-6G) to form a multi-layeredupper (e.g., an upper including layers such as those depicted in FIG. 7)is now described with reference to FIGS. 8-10. This embodiment relatesto formation of an upper by spray coating/depositing one or more layerson a last and then removing the upper and turning it inside out as thefinal product, such that the layer first sprayed on the last becomes theexterior layer of the upper and/or the surface of such layer engagingthe last becomes the exterior surface layer of the upper.

Referring to the flowchart of FIG. 8, at 805, a shoe last is providedhaving structural features formed on portions of its exterior surface(e.g., ribs 270 and channels 260 for last 200, or the surface featuresas shown for the last 400 of FIGS. 4A-4C or the last of FIGS. 6A-6G). Aspreviously noted, the structural features can be of any suitable typesand configurations so as to impart a reversed or inverted contour or anegative image of the structural features of the last on the firstsprayed structural layer on the last which forms the exterior surface ofthe upper.

At 810, the last is treated prior to application of the first sprayformed structural layer for the upper. Pretreatment of the last caninclude heat treatment of the last and/or the addition of certainmaterials to the last to facilitate easy removal of the upper from thelast after its formation as well as the addition of certainembellishments that will adhere to the initial or first sprayedstructural layer of the upper (i.e., the layer which will have a surfacedefining the exterior of the upper). Depending upon the chemicalmakeup/compositions of at least the initial layer (which becomes theexterior layer of the upper) to be sprayed onto the last, it may bedesirable to heat treat the last such that it is at a certaintemperature prior to and/or during spray treatment and/or setting orcuring of the layer(s) forming the upper. The last can also be sprayedwith a mold release composition that minimizes or prevents adhesion orsticking of the layer sprayed directly onto the last. Any suitable moldrelease composition can be used that is suitable for the type ofmaterial to be initially spray formed onto the last.

Certain embellishments, such as structural components that provideaesthetic designs (e.g., a company logo, other design features) to theexterior of the upper can also be applied to selected areas of the last,where the embellishments become at least partially embedded within theexterior surface of the upper as the initial layer is sprayed over suchembellishments and formed on the last. Another pretreatment of the lastprior to forming the initial structural layer for the upper is to applya pre-coat of a colored emulsion or other colored coating that resultsin adhering to the initial structural layer sprayed onto the lastsubsequent to application of the pre-coat colored layer.

An example series of pretreatment steps associated with step 810 aredescribed with reference to the flowchart depicted in FIG. 9. Any one ormore of the pre-treatment steps may be performed, and the order ofperforming such steps can also be modified in any desired manner. Inthis example, at 905, the last is sprayed with a mold releasecomposition to facilitate ease of removal of the upper from the lastafter the upper has been formed. At 910, the last is optionally heatedto dry the mold release composition and/or to obtain a suitableoperating temperature of the last as one or more structural layers areapplied to the last and depending upon the chemical/structuralcompositions of the materials being sprayed (so as to achieve desiredproperties, curing and/or other chemical reactions of the materialssprayed on to the last in forming the one or more layers).

At 915, a pre-coat is applied to the last, where the pre-coatcomposition can be one or more paint emulsions having one or moredesired colors and/or other compositions (e.g., a PU composition) whichwill adhere to the exterior (i.e., first spray formed) layer of theupper. The pre-coat can further include chemical compositions havingother physical properties such as antimicrobial properties, hydrophobicproperties, etc. These physical properties (e.g., antimicrobialproperties, waterproof or water resistant properties, etc.) are thusimparted to the exterior surface of the spray formed upper. In addition,when pre-coating with paint emulsions, the spray patterning can beadjusted during application of paint emulsions having one or morecolors, where the paint emulsions can be sprayed in two or moredifferent directions as the paint emulsions are applied to the last.This can result in a unique transitional color effect, when the sprayedpaint emulsions are transferred to the surface of the first layerapplied to the last, particularly when the paint emulsions are sprayedin two or more directions onto the last at the raised, three dimensionalstructural components/features.

At 920, embellishments can be added to the last at one or more desiredlocations. The embellishments (e.g., aesthetic structure such as companylogos and/or other designs) can be pressed against the pre-coatedsurface of the last and held in place, e.g., by friction and/or stickingto the pre-coat which might be slightly dried (e.g., in a gel likestate) but still somewhat tacky (e.g., not fully cured, solidified,dried and/or hardened). While steps 915 and 920 are described in whichembellishments are added after a pre-coat (e.g., with emulsion paint),these steps can also be reversed in order (e.g., embellishments appliedto last prior to pre-coating with emulsion paint).

Referring again to the flowchart of FIG. 8, at 815 (after pre-treatmentof the last), a first layer is formed by spraying a polymer material(e.g., PU, polyester, polyolefin or polyether) over all or selectedportions of the last, including last portions that include the threedimensional exterior surface structural features (such as ribs 270 andchannels 260 of last 200, or the structural features of last 400 or last600). The polymer material can be, e.g., in a liquid, solid orsemi-solid/semi-liquid (i.e., a partially wet) state and/or can undergoone or more chemical reactions as the material is deposited onto thelast. The polymer material can be sprayed in any suitable manner andutilizing any one or more types of spray equipment.

For example, referring to FIG. 10A, an automated spray system isutilized in which a robotic arm 1010 including at least one spray nozzle1020 directs a flow of polymer material 1030 (e.g., as an aerosol orsuspension of closely packed particles and/or droplets of polymermaterial, where the polymer particles can be in a liquid, solid orsemi-solid/partially liquid state) onto the last, where the robotic arm1010 can move in one or more passes over selected portions of the last(where the robotic arm is programmed to move in a selected travelpattern over the last) to build up the first layer (e.g., layer 710) toone or more desired thicknesses. During this spraying of the first layeronto the last, the sprayed material forms over the structural featuresof the last which results in the formation of a reversed or invertedcontour (i.e., a negative image) of such features on the layer (e.g.,ribs 270 of the last 200 define corresponding channels 170 on thesurface of the layer 710 of upper 100, while channels 260 of the last200 define ribs 160 on the surface of the layer 710 of upper 100).Further, if any embellishments and/or emulsion paint or otherpre-treatment layer was applied to the last, the structural materiallayer applied to the last over such pre-treatment layer will adhere tosuch embellishments and/or pre-treatment layer (e.g., embellishmentswill become partially embedded within the sprayed on/spray formed layerwhile the emulsion paint adheres to the exterior surface of the sprayedformed layer). Thus, when the upper is removed from the last at the endof the process, the exterior surface of the upper (e.g., the exposedsurface of layer 710 of the upper 100) will include such embellishmentsand/or color features.

The spraying of the first (i.e., upper exterior) layer as well assubsequent layers onto the last (at step 815) can be performed so as toprovide a substantially uniform thickness over the last or,alternatively, to vary the thickness of the layer over the last. Forexample, it may be desirable to build up the layer to a greaterthickness along some portions in relation to other portions of theupper. For example, spray forming a layer can be performed to achieve agreater thickness at areas such as the heel end or heel cup of the upperin comparison to areas such as the vamp section, medial and/or lateralsides of the upper (e.g., to provide enhanced structural support for theupper along the heel or along the sides of the upper). In anotherexample embodiment, the thickness of the spray formed layer can bevaried such that the layer has a greater thickness at a lower end thatconnects with a sole structure, while the thickness gradient of thelayer changes in that it decreases (becomes thinner) as the layerextends upward toward an upper end of the upper. In applications inwhich a thickness gradient is imparted in the spray formed exteriorlayer such that the layer decreases in thickness from a lower (solestructure connecting) end toward an upper end of the upper can create aspeckled like effect for the exterior surface at the thinner layerportions.

The spraying technique can further be performed by varying thestructural composition of the material as it is sprayed along differentareas of the last to form the layer such that the upper layer that isformed has different physical characteristics in certain areas (e.g.,creating an upper layer having different physical properties indifferent locations or zones of the upper). For example, the density,precise chemical formulation, etc. of the polymer material being sprayedto form a single layer on the last can be modified at certain areas soas to vary physical features such as breathability/air permeability,weight, etc. of the layer at different locations of the upper whilemaintaining the same or similar thickness at all locations of the singlelayer.

The optional modifications in thickness (forming a layer having athickness gradient along selected directions of the spray formed layer),density (forming a layer having a density gradient along selecteddirections of the spray formed layer), chemical composition(modification in chemical composition of the material forming the layeralong selected directions of the spray formed layer), etc. for a sprayformed layer can be achieved in a number of different ways using one ormore spray form nozzles. For example, a spray system utilizing anautomated robotic arm that includes one or more spray nozzles can beprovided to spray the polymer material in one or more differentformulations (e.g., two or more PU materials having different densities)and at one or more spray velocities toward the last (e.g., changing thespray velocity from the spray nozzle in selected directions of sprayalong the last). In addition, controlling the traveling speed of therobotic arm as it sprays over the last to form a layer, and controllingthe number of passes (e.g., one pass, two passes, three passes, etc.)over the same surface area portions of the last by the robotic arm whilespraying material toward the last can be used to adjust physicalproperties such as layer thickness, layer density, layer chemicalcomposition along different locations of the spray formed layer. Theshape of the material spray or spray pattern from the nozzle can be ofany suitable type, such as flat or conical/cone shaped, depending uponthe spray nozzle utilized for a particular spray forming process, andthis can also be adjusted to achieve different properties for thematerial layer spray formed on the last.

Thus, the spray methods described herein facilitate modifying physicalproperties of the material within a single layer of the upper that isformed of the same or similar type of polymer material (e.g., PU) aswell as the structural properties of the upper (e.g., airpermeability/breathability, structural/reinforcing strength, etc.)within this single layer at different locations of the upper.

After the first layer has been formed at the desired thickness (orthicknesses) and/or desired density (or densities) along the last, theformed layer is allowed to at least partially dry and/or partially cure,at 820, prior to applying any further layer and/or structural componentsto the layer. Depending upon the polymer chemistries involved information of the layer (based upon the types of one or more polymermaterials used to form the layer), the layer may require a certainperiod of drying, hardening and/or curing time before further processsteps can occur. The last may also be heated during this time to enhance(e.g., accelerate) drying/curing/hardening of the material layer on thelast.

After a suitable time for drying/curing of the first polymer layer sprayformed on the last, the process can proceed, at 825, by applying anyfurther polymer layer and/or structural components as desired and thenallowing for sufficient drying/curing of the layer prior to applying anyfurther layers or components to such layer (i.e., repeating steps 815and 820).

In example embodiments, it may be desirable to only allow the materiallayer to partially dry or partially cure before any further layer and/orstructural component is deposited or spray formed over this layer. Forexample, during curing of a polymer material in the sprayed layer (e.g.,a PU material or a polyester material), the polymer material can becomegel-like or sticky/tacky while not being fully hardened or cured. It isdesirable to apply any further layer and/or structural component duringthe time period at which the polymer material within the layer is notfully cured/dried/hardened but instead only partially dried/cured andstill in a tacky or gel-like state. For example, application of afurther layer to an already formed layer can occur prior to the end ofthe cure time for the polymer material under its curing conditions butafter the polymer material has gelled (e.g., at a time period that isbetween the gel time and the cure time for the polymer material).Applying any subsequent polymer material layer during this periodfacilitates suitable adhesion between the two adjacent layers at theirinterfaces or boundaries (e.g., by chemical bonding and/or structuralengagement between the polymer materials of the two layers at suchinterface or boundary). Such adhesion between adjoining layers can beachieved via the spray forming process without any lamination of thelayers together or laminate disposed between the layers and/or withoutany other adhesive material required to secure the two layers together.

Referring again to FIG. 7, a next or successive layer can be sprayformed over the most recently spray formed layer prior to this layerbeing fully dried, hardened and/or cured. This can result in a portionof the next spray formed layer combining (e.g., partially overlapping)with the already formed layer at the interface or boundary so as to forma thin transition zone at such boundary, where the transition zone cancomprise combinations of sprayed material forming each of the twoadjoining layers. As depicted in the example embodiment of FIG. 7, atransition zone 735 is formed during the spray forming process in whichlayer 720 is already spray formed over layer 710. In particular, thefirst or initial spray formed layer 710 can comprise a material A, whilethe next, subsequent or second spray formed layer 720 can comprise amaterial B. The transition zone 735 formed at the boundary betweenlayers 710 and 720 comprises a combination of materials A and B.Materials A and B can be materials that comprise completely differentchemical compounds (e.g., material A comprises PU while material Bcomprises polypropylene staple fibers mixed or combined with a bindermaterial). Alternatively, materials A and B can comprise the same basicchemical compounds that differ in densities, molecular weights and/orother physical properties (e.g., material A can comprise a first PU, andmaterial B can comprise a second PU that has a different molecularweight and different density in relation to the first PU). Similarly, atransition zone 740 is formed during the spray forming process in whichlayer 730 is spray formed over layer 720, where layer 730 can comprise amaterial C that differs from material B and the transition zone 740includes combinations of materials B and C.

The combination of the two adjoining layers that defines the transitionzone at their boundaries and that includes a combination or mixture ofthe materials used to form the two adjoining layers can have a thicknessthat is much smaller (e.g., 10% or less in thickness) than the thicknessof one or both of the spray formed layers adjoined to each other. Inaddition, a density gradient exists for each material within thetransition zone. For example, and referring again to FIG. 7, the densityof material A in transition zone 735 decreases from a greater densityvalue to a smaller density (eventually approaching zero) in a directiongoing from layer 710 to 720 (as shown by arrow A). Similarly, thedensity of material B in transition zone 735 decreases from a greaterdensity value to a smaller density (eventually approaching zero) in adirection going from layer 720 to 710 (as shown by arrow B1). Thedensity of material B in transition zone 740 decreases from a greaterdensity value to a smaller density (eventually approaching zero) in adirection going from layer 720 to 730 (as shown by arrow B1), while thedensity of material C in transition zone 740 decreases from a greaterdensity value to a smaller density (eventually approaching zero) in adirection going from layer 730 to 720 (as shown by arrow C).

Any structural components that are desired to be formed as part of theupper can be applied by adhering a preformed structural component to thetacky surface of the not fully dried and/or not fully cured layer,followed by spray forming any further polymer layer over the existinglayer with structural component adhered to such layer. In certainembodiments, this can result in securing and embedding of the structuralcomponent between the two spray formed layers, where the structuralcomponent provides enhanced strength and support in the upper at thelocation in which the structural component is provided due, e.g., to thestructural component having a greater hardness (e.g., a greater harnessor durometer value, such as a greater Shore A hardness value) inrelation to the layers between which the structural component isembedded. Structural components can be formed of any suitable polymerand/or other material (e.g., harder plastic materials such as nylon).Alternatively, the structural support can be spray formed on a portionof the already formed layer (e.g., at a heel location of the last),where the polymer material that is spray formed may be spray formed as aharder material (e.g., a harder material has a greater durometer valuein relation to a softer material, which can be measured, e.g., as aShore A hardness value) at the locations in which a structural componentis desired. The structural support material can even be of the samepolymer type (e.g., PU or polyester) as the adjacent, underlying(already spray formed) polymer layer but having a different density orother physical characteristic that renders the structural components asformed to have a greater hardness (e.g., greater Shore A hardness) inrelation to the underlying layer. As described in further detail herein,a variety of different types of structural components can be embeddedbetween spray formed layers of the upper.

After all of the layers have been formed and sufficiently dried and/orcured, the formed upper can be removed from the last and inverted, beingturned inside out (at 830, also depicted in FIG. 10D), where the firstspray formed layer on the last (e.g., layer 710) becomes the exteriorlayer and the last spray formed layer (e.g., layer 730) becomes theinterior or foot facing layer of the formed upper. In an exampleembodiment, the upper can basically be pulled or peeled back from thelast such that it is turned inside out as it is removed from the last(where the mold release composition inhibits or minimizes undesirablesticking of the initial sprayed on/spray formed layer to the lastsurface).

In addition to three dimensional structural surface features beingimparted to the exterior (“skin”) layer of the upper by the last, thelast can also impart other features to more than just one layer of theupper. For example, openings or eyelets can be formed in the upper basedupon protrusions provided on the last (e.g., cylindrical protrusions 255of last 200, cylindrical protrusions 455 of last 400, cylindricalprotrusions 655 on last 600) which have greater lengths (i.e., extendfurther) than the combined thickness of the plurality of layers sprayformed on the upper. For example, when the spray formed upper is pulledor peeled back from the last and turned inside out (as depicted, e.g.,in FIG. 10D), openings are defined at locations of the uppercorresponding with the projections on the last (e.g., eyelets 155 forupper 100, eyelets 355 for upper 300, eyelets 555 for upper 500).

Further, for embodiments in which the last is also configured to definea tongue portion or tongue member for the upper (e.g., tongue formingportion 445 for last 400 or tongue forming portion 645 for last 600,which facilitates that spray forming of tongue portion 345 for upper 300or tongue portion 545 for upper 500), the spray forming process includesspray forming material over the tongue forming portion of the last toform the tongue member of the upper. As previously described herein, thetongue forming portion of the last can include an upper/outwardly facingsurface (e.g., surface 446 of last 400) onto which material is sprayformed, and such surface can be slightly raised to define a sharplyangled transition to other surface portions of the tongue formingmember, where this sharply angled transition can facilitate easyseparation/removal of the tongue portion of the upper during peelingback of the upper from the last. Alternatively (e.g., refer to last600), the tongue forming portion can be contoured with the shape of thevamp portion of the last and still form a tongue portion that iscontinuous/integral with the formed upper.

An optional final step in forming the upper (step 835) involves furtherheating and/or other processing to set the upper in its final shape. Forexample, in certain embodiments (depending upon materials used to formlayers, dimensions of layers, structural components within and/orbetween layers, etc.), and due to the switching or flipping of theorientation of the interior and exterior layers of the upper uponremoval from the last and switching its configuration from inside toout, the upper may have some slight deformations in certain locations.As a further optional step, the upper can be re-lasted or placed back onthe last (or another last having similar dimensions as but not includingthe exterior structural surface features of the last used to form theupper) in its inside out or final configuration (i.e., with the exteriorlayer having the structural features, such as layer 710 of upper beingin the exterior layer configuration) and at a suitable time period afterforming the final layer (e.g., prior to the final layer being fullycured) so as to allow the upper to take its final relaxed form and shapeand remove any potential deformations caused by its removal from thelast (e.g., to align surface portions of the upper in their finaldesired shapes and configurations). In addition, the upper can also beheat treated while being re-lasted (e.g., at a temperature suitably lessthan the softening and/or melting temperature of at least one or all ofthe materials forming the upper) so as to enhance and/or accelerate thisprocess.

Structural Features Achieved for the Upper Utilizing the Spray FormingProcess

The spray forming process described herein facilitates the formation ofa composite upper including a plurality of distinct or indistinct layersand in which at least one exposed layer (e.g., the exterior layer) hasfine structural surface features imparted by corresponding structuralfeatures on the last. The process provides a number of benefits forforming uppers with a wide variance in physical properties at one ormore different locations of the upper while also facilitating relativeease of production. Some examples of beneficial features imparted bythis spray forming process are described as follows.

Internal structural components can be provided between layers of thespray formed upper (i.e., the structural components are embedded withinthe upper) to strengthen or provide structural support at differentlocations for different purposes. Some non-limiting examples of internalstructural components include one or more heel structural supportelements or heel counters that are applied to a layer located at theheel end of the last, one or more structural components that areprovided along the surface of the layer that correspond with medialand/or lateral forming sides of the last, one or more structuralcomponents provided at the toe cage of the last (e.g., to strengthen theupper and provide added protection to the user's toes at the toe cagelocation), one or more metal or polymer annular ring members provided atsuitable locations at or near the neck of the upper to providestructural support for eyelet openings (used for engaging with a shoelace or other fastener of the shoe), etc. In addition to formingstructural components between two layers of the upper, structuralcomponents can also be added during the formation of a single layer(e.g., during multiple spray passes used to form a single layer) so asto secure and embed the structural component within the single layer.

In an example embodiment depicted in FIGS. 11A-11C, eyelet strengtheningcomponents having an annular shape (e.g., metal annular components ormetal rings, textile annular components or textile rings, etc.) 1110 canbe placed over a spray formed layer (e.g., the first spray formed layer710 that becomes the exterior “skin” layer of the upper, as shown inFIGS. 11A and 11B) and around eyelet forming protrusions 255 on the last200 prior to spray forming another layer over the spray formed layer.The eyelet forming protrusions 255 comprise elongated (e.g.,cylindrical) members that extend from the exterior surface of the last1100. In FIG. 11C, a successive layer (e.g., layer) 720 is spray formedover the present layer (layer 710) and the components 1110. This resultsin embedding of the eyelet strengthening components 1110 within theupper (i.e., between layers of the upper) at the eyelet openinglocations (i.e., at locations corresponding with the protrusions 255 onthe last 200).

In another example embodiment depicted in FIGS. 12A-12C, structuralsupport elements are provided on a spray formed layer (e.g., layer 710)of a last 1200. In particular, a curved member 1210 is provided aroundthe heel end over the layer of the last 1200 (see FIGS. 12A and 12B),where the curved member 1210 can function as a heel counter (e.g., astructural heel support element) for the spray formed upper. Anelongated member 1220 can be provided on the spray formed layer alongone or both of the medial and lateral sides (e.g., to function in thespray formed upper as side structural support elements for the upper),while a further curved member 1230 can be provided on the spray formedlayer at the toe cage portion of the last 1200 (e.g., to function in thespray formed upper as a toe cage protection member or element for theupper). A successive layer (e.g., layer 720) is then spray formed overthe existing layer (e.g., layer 710) so as to cover and embed thestructural support elements 1210, 1220 and 1230 between layers of theupper. The structural components can be formed of any suitable materialsthat provide sufficient support for their intended purpose. An exampleembodiment of a material used to form an embedded structural componentis a polyamide material (e.g., nylon) or other suitable polymermaterial, a metal material, etc.

In addition, any of the layers can be spray formed as a nonwoven orother fibrous material layer (e.g., a fabric or textile layer). Afibrous material can also be spray formed or applied as an embeddedstructural component at any suitable locations on the last to provide adesired functional property for the spray formed upper. A fibrousmaterial, as used herein, refers to any material that includes fibers orfilaments that can be spray formed on the last or, alternatively, thatcan be preformed and applied to the last (e.g., to function as anembedded structural component of feature). Some example embodiments offibrous material include, without limitation, a nonwoven web ofcontinuous filaments that are spray formed on or that are preformed andapplied to the last (e.g., onto a layer already spray formed on thelast), staple fibers that are spray formed on or that are preformed andapplied to the last (e.g., on a layer already spray formed on the last).In a further example embodiment, staple fibers can be combined with asuitable polymer or other binder material and spray formed onto the last(e.g., on a layer already spray formed on the last).

As previously noted, the filaments or fibers forming the nonwovenmaterial layer can be formed from any suitable one or more types ofpolymer materials typically utilized for forming nonwoven fibrous websincluding, without limitation, polyolefins (e.g., polyethylene,polypropylene, etc.), polyesters (e.g., polyethylene terephthalate), andpolyamides (e.g., nylon), including fiber combinations that provide adesired elasticity to the nonwoven web such as elastane fibers (e.g.,elastic PU, such as the types commercially available as Lycra orSpandex). The filaments or fibers can also have varying cross-sectionalgeometries with fiber types including, without limitation, side-by-sidebicomponent or multi-component (i.e., two or more different polymertypes forming a filament), sheath-core, island-in-the-sea, etc. Byvarying amounts and types of polymer materials (as well as filamentcross-sections of such polymer materials) within the fibers/filamentsused to form the nonwoven web fibrous layer, various physicalcharacteristics of this layer can be controlled (e.g., breathability orair/moisture permeability, elasticity, moisture absorption, etc.).

By selecting an appropriate spray system including suitable polymermaterials and a spray nozzle 1020 suitably configured to direct a flowof one or more polymer fibers or filaments toward the last, a nonwovenweb (i.e., a web of entangled polymer fibers or filaments) or otherfibrous material (e.g., staple fibers or staple fibers combined with abinder material) can be formed of any suitable thicknesses and densities(either uniform or varying over the fibrous material layer). Anysuitable fibrous material layer (i.e., a material layer that includespolymer filaments or fibers, such as staple fibers or continuousfilaments) can be spray formed on the last to form layers or embeddedstructural components of a spray formed upper. The spray formed fibrousmaterial layer can also be allowed to dry to a sufficient degree priorto spray forming any further layer upon this layer.

In an example embodiment, fibers or filaments can be spray formed ascontinuous filaments that deposit over the last at selected locations soas to form a nonwoven layer or fibrous mat type layer at the depositedlocations.

In another example embodiment, staple fibers can be spray deposited in asuitable binder material (e.g., a polymer binder) to form a spray formednonwoven or other fibrous material layer. For example, a fibrousmaterial composition can include staple fibers of sufficient length(e.g., at least about 0.01 mm in length and no greater than about 20 mmin length) provided within a binder material. The binder material cancomprise, e.g., a suitable organic solvent (e.g., a C2-C12 alkane,ether, alcohol, ketone or ester) combined with a suitable blockcopolymer (e.g., a polystyrene-polybutadiene-polystyrene blockcopolymer) such that, when combined with the staple fibers, the bindermaterial provides a suitable viscosity for the fibrous materialcomposition to be sprayed onto the last.

Any number of subsequent layers of any suitable types (sprayed formedpolymer layer, sprayed formed foam layer and/or sprayed formed nonwovenor other fibrous material layer) can be spray formed on the previouslayer (i.e., by repeating steps 815 and 820 of the spray formingprocess), where the thicknesses of the layers can be selected based upona particular application and the polymer material used to form suchlayers.

In the example embodiment of an upper including layers 710, 720 and 730(FIG. 7), the first spray formed layer 710 can comprise an elastomericPU material that forms the exterior plastic “skin” layer of the upper,the second layer 720 can comprise a foam material, such as a PU opencell foam material that differs from the PU plastic material forminglayer 710, and the third layer 730 can be any suitable nonwoven or otherfibrous material layer or other suitable polymer skin layer that formsthe interior foot facing surface of the upper. As depicted in FIGS. 10Band 10C, the second layer 720 and third layer 730 are formed over layer710 (formed by the first structural material layer spraying as depictedin FIG. 10A).

The spray forming process for manufacturing the upper can result in afully seamless upper (i.e., no seams are in the upper), particularlywhen the upper is spray formed with one or more layers around a single,three dimensionally shaped last (i.e., there is no combination of two ormore molds defining a single surface around which the layers are sprayformed).

In particular, in the process in which the upper is formed such that thefirst spray formed structural layer on the last becomes the outermost,exterior surface layer of the upper (due to the upper being turnedinside out after it is formed on the last), the outermost spray formedlayer on the last (i.e., prior to removal of the upper from the last)can be spray formed so as to have a relatively smooth and seamlessexposed surface (i.e., the surface which becomes the interior or footfacing surface of the upper after it has been turned inside out). Thisavoids or minimizes undesirable seams or other surface contours on theinterior surface of the upper that might cause friction and irritationto a user's foot.

Polymer material layers that are spray formed on the last can be formedso as to impart a variety of different physical characteristics betweenlayers at different locations of the upper and even different physicalcharacteristics in a single layer at different locations of the upperover which such layer extends. The automated spray system, which caninclude a robotic spray arm, can be equipped with multiple spray nozzlesso as to provide a number of different features within a single sprayformed layer. For example, the multiple spray nozzles can be manipulated(e.g., via an automated process) to spray the same type of polymermaterial (e.g., PU) but having different densities and/or other physicalcharacteristics at different locations of the same spray formed layer.In one embodiment, PU having a first density is sprayed at the locationsof the last that define the lateral and medial sides of the upper and PUhaving a second density that differs from the first density is sprayedat locations of the last that define the heel cup and toe cage of theupper such that the two types of PU are defined within a single layerspray formed on the last (e.g., the first layer which forms the exteriorlayer of the upper after it is removed from the last and turned insideout).

In other embodiments, two different types of polymer materials may bespray formed within a single layer (e.g., using two separate spraynozzles of the robotic spray arm). In one such embodiment, a combinationof two or more different polymer materials (e.g., PU and polyester) canbe sprayed together over the desired locations of the last and thuscombined to form the single layer at such locations. In otherembodiments, the two or more different polymer materials (or differentcombinations of polymer materials) can be spray formed at separatelocations but combining at their interfaces so as to define a single,integrated layer of the last. For example, for the first spray formedlayer (which becomes the exterior layer of the upper), a first polymermaterial (e.g., PU) can be spray formed at certain locations of the last(e.g., the lateral and medial side locations) while a second polymermaterial (e.g., polyester or polyether) can be spray formed at otherlocations of the last (e.g., the heel cup location and/or the toe cagelocation) and the different polymer materials forming the layer arecombined at their interfaces by the spray forming process such that asingle, integral layer of the different polymer materials is formed.

Thus, various changes can be made during spray forming of one or morelayers on the last (e.g., changing densities or other physicalcharacteristics of the same polymer material type and/or changingpolymer materials or different combinations of two or more polymermaterials during spray forming passes to build a single layer) as aresult of using the automated spray forming system and methods describedherein.

The thickness of each layer of the upper can also be selectively andeasily controlled by the spray forming system and process, where thethickness of two or more layers can differ and the thickness of a singlelayer can be maintained generally uniform or varied at differentlocations of the layer (and different corresponding locations of theupper). The selection of thicknesses of each layer can be based upon anumber of factors including, without limitation, the types of polymermaterials used to form each layer, the desired functionalities andphysical properties desired for different locations of the upper basedupon different applications of use, etc.

Generally, for the exterior skin layer, the thickness can range fromabout 0.1 mm (millimeter) to about 10.0 mm or greater, such as fromabout 0.5 mm to about 3.0 mm or greater. Other layers of the upper canhave similar thickness dimensions (e.g., the inner skin layer or liningof the upper), while other layers can be much greater in thicknessdepending upon a particular application. For example, in embodiments inwhich a foam material layer such as PU foam is provided within the upper(e.g., layer 720 of the upper), the foam material can have the greatestthickness in relation to other layers and can further vary in thicknessat different locations of the upper (e.g., having thicknesses in certainlocations of about 100 mm or greater). In certain applications such as,e.g., basketball shoes, it may be desirable to provide additionalpadding or foam material along medial and/or lateral sides of the upperthat correspond with the user's ankle (so as to protect and minimize orprevent rolling of an ankle). In such scenarios, the foam layer can varyin thickness so to have its greatest thickness at the locationsrequiring more padding and protection for the user's foot.

Regarding the structural features that are formed on the exteriorsurface of the upper (e.g., ribs 160 and channels 170 of layer 710 forthe upper 100, or other structural features layer 710 such as thosedepicted for the upper 300 or the upper 500), the spray forming processfacilitates the formation of structural features having very intricateor fine dimensions and complex patterns. Since the desired structuralfeatures on the exterior surface of the upper are imparted as invertedor reversed in contour (i.e., a negative image) in relation to thecorresponding features on the exterior surface of the last, thisenhances the ease and ability to mass produce uppers having suchfeatures with little waste and while minimizing manufacturing time (thusminimizing production costs). The structural surface features (e.g.,ribs 160 and channels 170 for upper 100, or other three dimensionalshapes such as those depicted for uppers 300 and 500) can have anysuitable shapes dimensions, including any suitable lengths, widths andthicknesses or depths, where such shapes and dimensions are designed fora particular application and to provide a number of different functionalfeatures for the upper.

In example embodiments, the last can be designed to impart structuralsurface features to the exterior surface of the upper that have suitabledimensions and form selected shapes and patterns configured to make thecomposite upper resistant to tearing. Specifically, the surface featuresare configured to provide the composite upper with sufficient strengthand or control flexure along areas of the upper. In this manner the, thesurface features function as a “ripstop” or tear resistance feature thatprotects against or minimizes tearing or ripping of the upper alongcertain tear lines that might otherwise be imparted to the upper surface(e.g., as the upper is removed from the last during the last stage ofproduction). Depending upon the thickness of one or more layers of theupper and/or the overall thickness of the upper, one or more tear linesmight propagate within an upper, e.g., when the upper is removed fromthe last on which it is formed and/or when subjected to any otherfrictional, stretching and/or shearing forces. This can be an issue forany material layer that is spray formed around a mold, where the tearstrength can be diminished along certain weakened areas (e.g., areas inwhich a tear line might propagate quickly a portion of the layer inresponse to being subjected to certain pulling or stretching forces).The structural surface features, such as outwardly extending ribs and/orany other outwardly extending/thicker portions on the exterior surfaceof the upper, can prevent, inhibit or minimize any tear or at least asignificant propagation of a tear along the upper due to the increasingthickness of the layer material (as well as the overall thickness of theupper) at the locations of such structural surface features.

The ripstop or tear resistant functional features can be selectivelycontrolled, based upon selecting suitable dimensions for the structuralsurface features of the upper exterior surface, including length, width,thickness and depth of the structures, so as to prevent or minimizepropagation of rips or tears along the upper surface (within a layer ofthe upper and/or throughout the entire upper). In particular, the heightor thickness of outwardly extending structures (e.g., elongatedstructures or ribs) can be adjusted, based upon the type of polymermaterial used to form the layer and/or the location of the structures atthe exterior surface of the upper, to selectively control the bestripstop functionality (i.e., the best or enhanced minimization orprevention of ripping or tearing of the upper at such locations).Selecting suitable dimensions (in particular the height or thickness) ofthe raised ribs or other outwardly extending structures can be materialdependent. For example, ribs or other raised exterior surface structuresfor the upper can have thicknesses ranging from about 0.1 mm to about3.0 mm or greater, where the selected thickness can depend upon thepolymer material used to form the layer (e.g., about 1 mm or greater inthickness of ribs for a polyester material, about 2 mm or greater for apolyether or PU material, etc.) as well as the patterning of structuresalong the upper exterior surface. Raised or outwardly extending threedimensional structures can be aligned, for example, in a selectedpattern and/or number per selected surface area in locations of knownweakness in which tear lines along a layer can develop (so as toeffectively impart a ripstop at such locations that prevents orminimizes propagation of a tear along the tear line of the layer).

The last can further be designed such that sub-features ormicro-features are incorporated in the main or macro structuralfeatures. For example, ribs defined on the exterior surface of the uppercan further include micro structures, such as grooves and/or raisedsurface features along one or more surfaces of the ribs or otheroutwardly extending structure on the exterior surface of the upper so asto function as a roughened (i.e., non-smooth) surface portion for thestructure. This can be achieved, e.g., by etching and/or addingadditional micro-features on the larger sized or macro structuralfeatures formed on the exterior surface of the last. The formation ofthe last (e.g., by 3D printing, by etching or machining, or in any othersuitable manner) facilitates the formation of very elaborate structuralfeatures on the exterior surface of the last, including macro or largersized features and micro or smaller sized features disposed on the macrofeatures, that are imparted to the exterior surface of the upper. Forexample, for the repeating pattern unit of upper exterior surfaceportion 302 depicted in FIG. 3C for the upper 300, the hexagonal shapedthree dimensional structural components 310 comprise a series of steppedplatforms of structures that define varying thicknesses for the upper300 within the area defined by the repeating pattern unit of upperexterior surface portion 302. The smaller stepped pattern portions(i.e., the stepped pattern portions that occupy the smallest area of theexterior surface of the upper) can define micro structures in relationto the larger stepped pattern portions. Such elaborate and intricatethree dimensional patterning would be very difficult to achieve usingconventional techniques for forming an upper. With the spray formingprocess described herein, a variety of different three dimensionalstructural component patterns can be formed (with macro structures andmicro structures defined on the macro structures) on the upper.

Depending upon the number of layers used to form the upper, thematerials used to form the layers, the thicknesses of different layersand/or the overall thickness of the upper, any exterior structuralsurface features (e.g., three dimensional repeating patterns ofstructural features) formed on the outer (e.g., skin) spray formed layerof the upper can also be imparted or translated to the interior surfaceof the inner (e.g., lining) layer of the upper. In other words, in suchembodiments, three dimensional structural surface features provided tothe exterior surface for the outer layer of the upper also result informing corresponding three dimensional structural features on theinterior surface of the inner layer of the upper. In exampleembodiments, the imparted or translated three dimensional featurestranslated from the exterior layer surface to the interior layer surfacecan be a negative image or inverted/reversed in contour in relation tothe surface contour features of the exterior layer surface (e.g., thesurface pattern features on the interior surface of the upper can besimilar to the same features provided on the last). Providing an upperthat includes a three dimensional (i.e., uneven or non-smooth) contouralong the interior surface of the upper inner layer can providefunctional benefits for the upper, such as facilitating air flow (e.g.,warming or cooling) within the upper when worn due to the pockets orchannels that are created between the interface of the upper interiorsurface with the wearer's foot as a result of this three dimensionalcontouring.

The spray forming methods described herein further facilitate impartingbreathability (e.g., air and/or water or moisture permeability) atselected portions of the upper. Material layers can be easily formedwithin portions of the upper that have different levels of porosityand/or breathability as well as other functionalities, such as moistureabsorption. For example, a nonwoven or other fibrous material layer willtypically have greater softness (in feel and texture), greater porosity,greater breathability and greater moisture absorption than a sprayformed polymer layer (e.g., PU) that forms the outer, skin layer of theupper. However, such fibrous material layers may not provide as muchstructural strength or cushioning in certain areas of the upper wheresuch features are desired. Accordingly, it may be desirable to formnonwoven or other fibrous material layers at certain portions of theupper to achieve desired feel, breathability, etc. while still includinga plastic (e.g., PU) exterior or skin layer at other portions of theupper to achieve the desired strength and structural integrity of theupper at such portions.

The use of a spray formed nonwoven or other fibrous material layer inthe upper facilitates formation of a variety of different uppers inwhich one or more fibrous material layers are incorporated at differentlocations of the upper.

In one example embodiment, such as previously described herein, anonwoven fibrous material layer is provided primarily as an interiorlayer or lining for the upper (e.g., to provide moisture absorption anda soft feel against the user's foot). In this embodiment, the nonwovenmaterial layer can be provided along some or all of the interior surfaceportions of the upper, and the nonwoven material layer is not exposedalong the exterior of the upper. For example, the last spray formedlayer (e.g., layer 530 as shown in FIG. 5) can be a fibrous materiallayer such as a nonwoven material layer.

In other embodiments, the nonwoven or other fibrous material layer canbe formed so as to be exposed at one or more exterior portions of theupper. For example, the outer skin layer can be a harder plastic polymerlayer such as PU spray formed first on the last, where the outer skinlayer provides structural integrity for the upper and is formed (atleast at portions of the upper) as a mesh or cage layer having aplurality of openings to expose a second, nonwoven material layer sprayformed directly on the outer skin layer. To facilitate this formation, alast can be provided having raised structural surface features ofsufficient length, width and thickness dimensions, where the thicknessof the surface features can be about as large (e.g., as great as,slightly less than or slightly greater than) the desired thickness ofthe first layer to be spray formed on the last.

Referring to the example embodiment depicted in FIGS. 13A-13C, a last1300 includes raised structural component features 1305 (FIG. 13A) atselected locations along one or more of its sides. A first polymer layer(e.g., PU) is spray formed so as to be deposited around and primarily orentirely within the channels defined between the raised structuralcomponent features 1305 of the last 1300 (note that portion 1302 of thelast remains uncovered/not sprayed with polymer material to form theupper). While FIG. 13A only shows structural component features 1305 forthe last 1300 at a selected area of the last (e.g., along a lateral ormedial forming side of the last), it is noted that such structuralcomponent features can be provided along any one or more exteriorsurface areas of the last (e.g., along a majority of the exteriorsurfaces of the last).

The deposition of the polymer material by spray forming around thefeatures 1305 and within the channels defined between the features 1305can be achieved in a number of ways, including selective spraycoating/depositing of the polymer material so as to avoid the features1305 while spraying between the features 1305 (i.e., within the channelsdefined between the features), providing raised structural features thathave angled upper surfaces to facilitate draining or self-leveling ofthe polymer material into the adjacent channels as the polymer materialis spray coated on the last, providing chemically selective featureswithin surface portions defining the channels and/or chemicallyrepelling features on surface portions of the raised structures 1305 ofthe last 1300 (e.g., hydrophobic surface features, hydrophilic surfacefeatures, etc.) for the polymer material to be selectively spraydeposited within the channels, etc. Upon spray forming the first layer1310 on the last 1300, the layer 1310 can have a thickness that is thesame or substantially similar to (but slightly smaller than) the lengthsof the structural component features 1305 (FIG. 13B), such that openingsare defined within the layer 1310 at the locations of the features 1305,and these openings translate to openings visible at the exterior surfaceof the upper after it is formed and removed from the last 1300.

A nonwoven or other fibrous material layer 1320 (FIG. 13C) can be sprayformed over the last 1300 including layer 1310 (which will become theexterior polymer skin layer of the upper). The fibrous material layer1320 adheres to the polymer skin layer 1310 such that, when removed fromthe last 1300 and turned inside out, the exterior skin layer 1310 formsa mesh or cage-like structure for the upper 1350 (FIG. 13D) in the areascorresponding with the structures 1305 on the last 1300 that is adheredto the nonwoven material layer, where portions of the fibrous materiallayer 1320 are also exposed to the exterior of the upper 1350 at theexposed areas or openings defined by the outer skin layer 1310.

This embodiment provides the upper with excellent breathability featuresdue to the nonwoven material layer being exposed (i.e., not covered bythe polymer skin layer having reduced breathability) at different areasalong the upper while also having sufficient structural strength andintegrity imparted to the upper by the polymer mesh or cage layer at theouter surface of the upper. In such embodiments, a nonwoven materiallayer can be provided so as to form a continuous inner lining layer ofthe upper (while also being exposed to the exterior at selected exteriorsurface portions of the upper).

The external polymer skin layer formed as a mesh or cage can further beformed with openings having any suitable sizes and/or shapes. In certainembodiments and for certain applications, it may be desirable to formthe external polymer skin layer having openings such that the skin layermesh structure defines a plurality of auxetic shaped patterns.Alternatively, the exterior surface of the external polymer skin layercan also have raised, three dimensional exterior surface features thatcomprise auxetic patterns (e.g., certain structural surface patternfeatures as depicted for the upper 500 as shown in FIG. 5). Aspreviously noted, auxetics are structures or materials that have anegative Poisson's ratio such that, when stretched, they become thickerperpendicular to the applied force. The auxetic patterning of theexternal mesh polymer skin layer can impart certain features thatenhance certain physical properties of the upper when the upper isstretched during use.

For certain applications (e.g., where less breathability for the upperis desired and/or greater structural strength is required), a nonwovenor other fibrous material layer can be provided only at certain portionsof the upper and/or as an intermediate layer within a plurality oflayers of the upper. For example, one or more nonwoven web materiallayers can be formed at openings or “windows” defined within and atselected portions of the exterior skin polymer layer. The windows can bedefined, e.g., along lateral and/or medial sides of the upper where morebreathability may be desired, while the exterior polymer skin layer iscontinuous (i.e., no windows or openings exposing the nonwoven weblayers) at locations such as the heel end or toe cage of the upper. Insuch embodiments, nonwoven or other fibrous material layers can beselectively spray formed at only the locations of the last that definethe windows for the exterior polymer skin layer (e.g., at large raisedsurface structures defined on the last). The fibrous material layers canbe spray formed to cover and extend slightly beyond the window sectionsof the exterior polymer skin layer. Alternatively, an alreadyformed/preformed fibrous material (e.g., a section of a nonwovenmaterial web, or a section of staple fiber mat) can also be applied atthe window sections instead of being spray formed at such windowsections. A further polymer layer can then be spray formed over theportions of the exterior polymer skin layer that are not defined by thewindows, where the further polymer layer is also spray formed over atleast the edge portions of the nonwoven material layers so as to lockthe nonwoven material layers in place at the window locations of theupper.

An example embodiment of forming windows in a spray formed layer of anupper with fibrous material structural component embedded within theupper and covering such windows is described with reference to FIGS.14A-14E. Referring to FIG. 14A, a last 1400 includes exterior surfacestructural components comprising generally rectangular projections 1405extending from a main exterior surface of the upper 1400. Theprojections 1405 can be disposed, e.g., along lateral and medial formingsides of the last 1400. A first (e.g., PU) layer 1410 is spray formedover the last 1400 (FIG. 14B) to a thickness that is the same,substantially similar or slightly smaller than the lengths of theprojections 1405 (note that portion 1402 of the last 1400 is not spraydeposited with polymer material that forms the layer 1410 of the upper).Portions of, e.g., a fibrous material 1420 can be provided over thelayer 1410 at the locations of the projections 1405 (FIG. 14C). Thefibrous material can be spray formed over such locations. Alternatively,the fibrous material can comprise pieces of, e.g., a nonwoven fabricmaterial, a knit fabric material, a woven fabric material and/or anembroidered fabric material. Each piece of fibrous/fabric material 1420is suitably dimensioned to cover and extend slightly beyond (i.e., havea greater area than) the surface area of the corresponding opening inthe layer 1410 (as defined by the corresponding projection 1405) whichis covered by the fabric piece. A further material layer 1430 is thenspray formed over the last to cover layer 1410 and also a portion of theperimeters defined by each fabric material 1420 (FIG. 14D), thussufficiently securing each piece of fabric material 1420 between thelayers 1410 and 1430. For example, a mask can be used when spray formingmaterial layer 1430 over the last (where the mask is suitably alignedover the window locations that include fabric material 1420), such thatthe spray formed material layer 1430 does not cover fabric material1420. When the spray formed upper 1450 is turned inside out and removedfrom the last 1400 (FIG. 14E), openings or windows within the layers1410 and 1430 are covered by the fabric material 1420 to provide adesired porosity/breathability/air permeability for the upper 1450.

The embodiment of FIG. 14 is just one example of how windows can beformed in one or more layers of the upper (where the windows are formedin spray formed layers based upon structural components/raisedstructures provided on the last used to form the upper). In otherexample embodiments, the openings or windows in every spray formed layercan be formed/defined using a mask or plurality of masks.

In still further embodiments, a nonwoven or other fibrous material layercan be formed first on the last so as to become the exterior layerincluding exterior surface features imparted by the corresponding andnegative image features defined on the last. Other layers (e.g., a PUlayer, a polyester layer and/or a polyether layer) can then be sprayformed over the nonwoven material layer. Alternatively, the upper can beformed entirely of a spray formed fibrous material layer. In certainembodiments, structural components can also be applied to the sprayednonwoven material layer on the last, such as heel cup structuralcomponents (e.g., a heel counter element), lateral and/or medial sidewall structural components (to strengthen the structural integrity ofthese sides of the upper), etc. followed by a further spray forming ofnonwoven material over the structural components so as to lock suchcomponents in place within the upper.

Thus, the methods described herein facilitate the spray forming of anupper that includes nonwoven or other fibrous material within the upper(e.g., a single nonwoven material layer or a plurality of nonwovenmaterial layers including structural components disposed within a singlelayer or between two or more layers).

In further embodiments, a fibrous/fabric material layer, such as anonwoven, knit, woven or embroidered fabric layer, can be provided overa spray formed layer and then entirely embedded within the upper byspray forming a further layer entirely over the fibrous material layer.In such embodiments, the fibrous material layer can function as areinforcing (e.g., fabric scrim) material embedded within the upper toadd reinforcing structural support for the upper. In such embodiments,the embedded fabric layer can extend throughout the entire spray formedupper, through a majority (i.e., extending over 50% of the exteriorsurface defined by the upper) of the upper, or only at selectedlocations of the upper. Depending upon the type of fabric material to beembedded, the fabric material can either be sprayed onto the last (overan already spray formed layer) or preformed and applied to (e.g.,pressed against) the last prior to spray forming a further layer.

In further examples, a fabric material, such as a knit fabric, a wovenfabric, a nonwoven fabric, or an embroidered fabric, can be preformedand provided over a last to form a first layer. The fabric material canbe a single, unitary (e.g., sock-like) member or, alternativelyconstructed in pieces that are secured together in any suitable manner(e.g., via stitching, adhesives, fabric tape, etc.). A second polymermaterial layer can be spray formed over the fabric layer. Upon removalof the upper from the last and turning the last inside out, the upper isdefined by a fabric exterior surface and an interior polymer lining. Anysuitably types of structural components and/or further spray formedlayers can also be provided to form a multi-layer upper having a fabriclook on the exterior while also having structural support and/or otherdesired features provided by other layers and/or structural componentsembedded within layers of the upper.

Breathability/air permeability for the upper can also be impartedwithout the use of fibrous material layers and/or in combination withfibrous material layers. In some embodiments, perforations or holes canbe formed through at least the exterior polymer skin layer that iscontinuous (and optionally through other layers) of the upper so as toprovide for air permeability through this layer. For example, in anembodiment in which a spray formed upper includes three layers, such asa relatively unbreathable PU plastic polymer exterior skin layer, acentral PU open cell foam layer, and an inner nonwoven material layerforming the inner lining of the upper, perforations or holes can beformed within the PU exterior skin layer at selected locations of theupper to render a certain amount of breathability within the upper.Mechanical perforation of this exterior skin layer after it has beenformed can cause undesirable damage to the layer (e.g., increasing therisk of rips or tears in this layer). Forming perforations by laseretching or laser cutting can be utilized to reduce the risk of damage tothe layer. Utilizing the spray forming methods as described herein,external structural surface features can be provided on the last thatalso facilitate formation of perforations or openings in the exteriorskin layer during the spray forming of this skin layer.

In one embodiment, the last can include raised elongated structuralfeatures, such as pillars, spikes or pins that are aligned alongselected portions of and extend transversely from the exterior surfaceof the last. The raised elongated structures can have suitable lengthsand transverse dimensions (e.g., diameters or widths) that respectivelycorrespond with a desired thickness of the exterior polymer skin layerto be spray formed on the last and desired dimensions of theperforations to be formed within the skin layer. The polymer material(e.g., PU polymer) is spray formed on the last around the raisedelongated structures up to about the length or height of the structures,with the further layers (e.g., PU open cell foam layer and a nonwovenmaterial layer) then being spray formed over the skin layer. Removal ofthe upper results in the exterior skin layer having the perforations atthe locations corresponding to the raised elongated structures on thelast. In other embodiments, the perforations can be provided so as toextend through the entire thickness of the upper (i.e., the perforationsextend through the combined thicknesses of all layers of the upper),where the elongated structures on the last have sufficient lengths thatare greater than the overall or entire thickness of the upper that isspray formed over the last.

In another embodiment, the last can be formed as a hollow member thatincludes drain channels extending from the exterior surface of the lastto its hollow interior or interior cavity. In spray forming a firstlayer over the last, the sprayed material forms on the surface of thelast and drains at openings to the drain channels at the exteriorsurface of the last so as to define openings or perforations in thelayer corresponding with the last drain channel openings. The last canfurther be formed to include surface features along the channels thatinhibit or prevent adhering or sticking of the polymer material used toform the first sprayed layer along the channel walls and within thechannels. For example, in an embodiment in which the polymer materialthat is first sprayed on the last is hydrophilic (or is provided in acarrier that is hydrophilic), the drain channels extending through thelast can be formed such that the channel interior surface walls arehydrophobic (e.g., coated with a hydrophobic material) so as to inhibitadhering or sticking of polymer material draining through the channels(thus avoiding clogging of the channels). Thus, the last of thisembodiment facilitates forming the upper so as to include perforationsor openings in at least the external skin polymer layer.

In the embodiments described herein in relation to the drawings, thespray formed upper is formed as a single unitary three dimensionalmember that includes all of the boundary walls of the upper includingthe bottom wall (so as to be sock like in configuration) or to includeall boundary walls with the exception of a bottom wall (where, in suchembodiments, the upper can be secured to the sole structure via astrobel or other suitable bottom surface member). However, in otherembodiments, an upper can be formed with one or more spray formedcomponents that are then combined with each other or with othercomponents (e.g., thermoformed or other formed components) to form theupper, such that one or more spray formed components can be removed fromthe last so as to have a generally planar configuration. For example, aspray formed upper component having one or more layers can be formedover portions of the last corresponding with the toe cage, lateral andmedial sides of the upper, where such spray formed upper component(including structural features on the exterior skin surface) can then becombined with a heel cup member (e.g., a thermoformed heel cup member)and secured together (e.g., using a suitable adhesive, such as Bemistape or any other suitable adhesion) to form the upper.

The methods described herein can further facilitate formation of anentire shoe using a spray forming process. For example, one or moresuitable molds can be arranged in position with the spray formed upper(e.g., the spray formed upper can be re-lasted or placed on a last againafter it has been spray formed) and a sole structure (e.g., midsole orcombination of midsole with outsole) of one or more selected polymermaterials can then be spray formed or injection molded within themold(s) so as to adhere to lower surface portions or a bottom surface ofthe upper (e.g., when the upper is formed as a sock-like structure).

Referring to the flowchart of FIG. 15 and corresponding FIGS. 16A-16C, aprocess for forming an entire shoe (i.e., an upper combined with a solestructure) is described. The upper can initially be formed, e.g.,utilizing the process as described herein and depicted in the flow chartprocess steps of FIG. 8. At 1505, the formed upper, which has beenremoved from the last (e.g., as depicted in FIG. 10D) can be placed on alast (the same last used to spray form the upper or, alternatively, adifferent last) in its final form such that the exterior surface of theupper remains exposed while on the last. As shown in FIG. 16A, an upperis fit on a last 1600 having its exterior surface 710 facing outward(i.e., away from the last). In this embodiment, the spray formed upperis formed as a sock-like structure including a bottom side.

At 1510, the last including the upper can be placed within a mold (ifthe process includes injection molding). The mold can enclose a portionof the last with upper or, alternatively, entirely enclose the last withupper. The mold further includes a cavity such that, when the last withupper is partially or entirely secured within the mold, the cavity islocated below a lower surface of the upper (see FIG. 16A, upper withlast 1600 is fit within a mold 1605 such that a mold cavity 1610 islocated directly below a bottom surface of the upper). Alternatively,the sole structure can be spray formed onto the bottom surface of theupper in a manner similar to spray forming layers onto the last to formthe upper.

At 1515, polymer material is injected molded into the mold cavity or, ifspray formed, sprayed onto the bottom surface of the upper to form thesole structure (see, e.g., FIG. 16A, sole structure forming polymermaterial is injected into the cavity 1610 with an injection nozzle1620). The mold can be configured such that one or more different typesof polymer material are sprayed or injected into the mold cavity. Thisfacilitates the formation of a sole structure formed of a singlematerial or a sole structure formed of a combination of differentmaterials that define different portions of the sole structure. Forexample, a sole structure can be formed with a midsole structurecomprising a midsole material that provides a cushioning layer for theshoe and an outsole structure comprising an outsole material that isharder than the midsole material (i.e., the outsole material has agreater Shore A hardness value than that of the midsole material) andprovides a durable, abrasion/wear resistant ground-engaging surface forthe shoe. At FIG. 16B, the sole structure 1630 is formed by polymermaterial injected or spray formed within the mold cavity 1610, where thepolymer material adheres to the bottom surface of the upper. After thesole structure has sufficiently dried, hardened and/or cured, the upperwith last 1600 can be removed from the mold 1605 (FIG. 16C).

In further embodiments for forming a shoe, structural elements, such asa hard plate (e.g., a nylon plate) or other suitable structure can beembedded by the spray forming or injection molding process used to forma sole structure at the bottom of the spray formed upper. In an exampleembodiment, a first polymer layer can be spray formed over the bottomsurface of the upper (e.g., while the upper is supported on a last), anylon plate or other suitable structural component can be applied to thesprayed formed layer, and a further layer can then be spray formed overthe structural component so as to embed the structural component betweenthe two spray formed layers (i.e., to embed the structural componentwithin the sole structure formed at the bottom of the upper).

While the invention has been described in detail and with reference tospecific embodiments thereof, it will be apparent to one skilled in theart that various changes and modifications can be made therein withoutdeparting from the spirit and scope thereof.

It is to be understood that terms such as “top”, “bottom”, “front”,“rear”, “side”, “height”, “length”, “width”, “upper”, “lower”,“interior”, “exterior”, and the like as may be used herein, merelydescribe points of reference and do not limit the present invention toany particular orientation or configuration.

What is claimed:
 1. An upper for an article of footwear, the uppercomprising: a spray formed first layer comprising a first material; anda second layer comprising a second material, the second layer beingadhered to the first layer; wherein a transition zone is defined at atransition between the first layer and the second layer, the transitionzone comprising a mixture of the first and second materials.
 2. Theupper of claim 1, wherein the second layer is a spray formed layer, andthe upper further comprises: a spray formed third layer comprising athird material, the third layer being adhered to the second layer. 3.The upper of claim 2, wherein the second material comprises apolyurethane foam material.
 4. The upper of claim 3, wherein the firstmaterial comprises a polyurethane material that has a greater densitythan the polyurethane foam material.
 5. The upper of claim 1, whereinthe first layer includes an exposed surface that defines an exterior ofthe upper, and the exposed surface includes three dimensional structuralsurface components disposed at portions of the exposed surface.
 6. Theupper of claim 5, wherein at least 50% of the exposed surface includesthree dimensional structural surface components.
 7. The upper of claim6, wherein the structural surface components include a three dimensionalpattern that repeats over a portion of the exposed surface.
 8. The upperof claim 6, wherein the structural surface components disposed along theexposed surface include raised rib structures and channels disposedbetween the rib structures.
 9. The upper of claim 6, wherein thestructural surface components comprise an arrangement of surfacecomponents in a plurality of different patterns.
 10. The upper of claim9, wherein a pattern of surface components comprises a plurality of arcshaped ribs with arc shaped grooves disposed between the arc shapedribs, and the pattern is located along a side and at a toe end of theupper.
 11. The upper of claim 6, wherein the structural surfacecomponents comprise a pattern of three dimensional auxetic structures.12. The upper of claim 1, wherein the second layer comprises a textilematerial.
 13. The upper of claim 12, wherein the textile materialcomprises a preformed fabric material selected from the group consistingof a knitted material, a woven material, a nonwoven material and anembroidered material.
 14. The upper of claim 1, wherein the second layercomprises a spray formed fibrous mixture of staple fibers combined witha binder material.
 15. The upper of claim 1, further comprising astructural component embedded between the first and second layers,wherein the structural component has a greater hardness value than ahardness value for each of the first and second layers.
 16. The upper ofclaim 15, wherein the structural component is located at a heel end ofthe upper, at a toe end of the upper or along a lateral or medial sideof the upper.
 17. The upper of claim 15, wherein the structuralcomponent comprises an annular member aligned with a correspondingopening extending through each of the first and second layers.
 18. Theupper of claim 1, wherein the first layer forms an exterior layer of theupper and includes an opening extending through the layer to expose aportion of the upper underlying the first layer.
 19. The upper of claim18, wherein a textile material is disposed between the first and secondlayers at the opening.
 20. The upper of claim 18, wherein the secondlayer comprises a textile material, and a portion of the second layer isdisposed at the opening.
 21. The upper of claim 1, wherein one or bothof the first and second layers is seamless.
 22. An article of footwearcomprising: the upper of claim 1; and a sole structure adhered to theupper.